Fabrication of piezoelectric ceramic/polymer composites by injection molding

Ceramic injection molding has been shown to be a viable process for fabricating both PZT (lead zirconate titanate) ceramics and piezoelectric ceramic/polymer transducers. The electrical properties of injection-molded PZT ceramics are comparable with those of ceramics prepared by conventional powder pressing, with no evidence of deleterious effects from metallic contamination and molding equipment. By using ceramic injection molding to fabricate composite preforms and then laying up the preforms to form larger composite arrays, an approach has been demonstrated for net-shape manufacturing of piezoelectric composite transducers in large quantities. The authors review key features of the ceramic injection molding process, and describe the approach and methodology being used to fabricate the PZT ceramic/polymer composites