Net shape manufacturing of ceramic micro parts with tailored graded layers

Presented in this paper is a novel net shape manufacturing technology for making three-dimensional micro parts with functionally graded layers. Alumina/zirconia micro parts with either core–shell or top–bottom functionally graded material (FGM) profiles have been successfully fabricated by altering both the surface characteristics of polydimethylsiloxane (PDMS) micro moulds and ceramic suspensions composition. PDMS surface modifications were performed to achieve moulds with hydrophilic surfaces, which were used to form core/shell FGM green layers. On the other hand, moulds with hydrophobic surfaces were used to form top–bottom green layers. Cracks have been found between consecutive layers in both the green and sintered micro parts. It was found that, at dispersant concentration of about 9.0 mg g−1, the differences in the drying shrinkage between layers is less than 0.5%. In addition, layers of composition of 100% Al2O3–0% YSZ, 20% Al2O3–80% YSZ and 40% Al2O3–60% YSZ were found to produce less shrinkage difference during sintering. After optimization of both green and sintering layers, crack free core/shell and top–bottom alumina/zirconia FGM micro parts were successfully obtained. The proposed process enables the production of micro patterns tailored with functionally graded microstructures to locally enhance properties and performance.