Fabrication of three-dimensional inter-connective porous ceramics via ceramic green machining and bonding

A novel method is demonstrated to fabricate three-dimensional inter-connective porous ceramics with engineered structures. The method is based on machining and bonding of ceramic green sheets. The ceramic green sheets were processed via a viscous polymer processing (VPP) route using thermoplastic (polyvinyl butyral) as a binder, which showed good machinability and surface finishing quality. The experimental results also revealed that an appropriate solvent and adequate applied pressure were critical to ensure good interfacial bonding between green ceramic sheets and subsequent integrity of the sintered three-dimensional inter-connective ceramic bodies. The architectures and microstructures of fabricated ceramic bodies can be readily controlled by the characteristics of the green body and the computer numerically controlled machining conditions.