Processing of Piezocomposites by Fused Deposition Technique

Piezoelectric ceramic/polymer composites were made by a fused deposition (FD) technique, which is a solid-freeform fabrication (or layered manufacturing) technique where three-dimensional (3-D) objects are built layer by layer from a computer-aided design (CAD) file on a computer-controlled fixtureless platform. Indirect and direct FD methods were used to fabricate lead zirconate titanate (PZT)/polymer composites. For the indirect method, a CAD file for the negative image of the final part was created. A polymer mold was made via FD using a thermoplastic filament, and composite formation was completed via a lost mold technique. In the direct FD method, a thermoplastic polymeric filament that was filled with 50–55 vol% of PZT powder was used to form a positive image of the desired structure. Three-dimensional honeycomb (“3-D honeycomb”) composites and “ladder” composites with 3-3 connectivity, which were formed via the FD technique, showed excellent electromechanical properties for transducer applications. In addition, the FD technique showed the ability to form composites with controlled phase periodicity, various volume fractions, and a variety of microstructures and macrostructures that are not possible with traditional composite-forming techniques.