We are proposing an innovative concept and technology, Soft Solution Processing (SSP) for ceramics, which aims to achieve direct fabrication of shaped, sized, located, oriented ceramic materials from solutions without firing and/or sintering. We have successfully fabricated thin and thick films of BaTiO3, SrTiO3, BaWO4, SrMoO4, LiCoO2, and LiNiO2 by SSP in aqueous solutions from room temperature to 200 °C. In these experiments, interfacial reactions between a solid reactant (substrate) and component(s) in a solution have been designed and realized. By locally activating the reaction and moving the reaction point dynamically in these reactions, we can produce patterned ceramics directly in solution without masking, etching, pattern forming, or any post-heating such as firing or sintering. In this paper we present recent results for patterned ceramic films of PbS, CdS, and LiCoO2. The processes used to produce these films are entirely new, and represent the first examples of successful direct patterning of ceramics from solutions. In previous reports, heating processes have been essential for synthesis and/or sintering of powders and precursors to obtain patterns in ceramic materials. Such processes inevitably cost environmentally and economically. In contrast, our method, where no firing is needed, provides an environmentally and economically less expensive alternative.

Tissue engineering aims to produce biological substitutes to restore or repair damaged human tissues or organs. The principle strategy behind tissue engineering involves seeding relevant cell(s) onto porous 3D biodegradable scaffolds. The scaffold acts as a temporary substrate where the cells can attach and then proliferate and differentiate. Collagen is the major protein constituent of the extracellular matrix in the human body and therefore an attractive scaffold material. Current collagen scaffolds are foams which limit the mass transport of oxygen and nutrients deep into the scaffold, and consequently cannot support the growth of thick-cross sections of tissue (greater than 500 μm). We have developed a novel process to make collagen and collagen-hydroxyapatite scaffolds containing an internal artificial circulatory system in the form of branching channels using a sacrificial mould, casting and critical point drying technique. The mould is made using a commercial rapid prototyping system, the Model-Maker II, and is designed to possess a series of connected shafts. The mould is dissolved away and the solvent itself removed by critical point drying with liquid carbon dioxide. Processed hydroxyapatite has been characterised by XRD and FTIR analysis. Tissue engineering with collagen scaffolds possessing controlled internal microarchitecture may be the key to growing thick cross-sections of human tissue.

The production of functional tool steel components by selective laser sintering requires an understanding of the effects of the laser processing parameters on the microstructure evolution during the fabrication process. This would allow the production of tools that have predictable and reproducible microstructure, good mechanical properties and low residual stresses. In this paper, finite element modelling has been carried out to investigate the temperature distribution and residual stresses during laser sintering of hot-work tool steel powders. The effects of the laser power and scanning rate on the selective laser sintering process have been investigated. Thermal residual stresses accumulated during the process have been predicted and compared with strain measurements made using neutron diffraction.

The direct ink-jet printing of ceramic powders requires the development of highly fluid suspensions of ceramic particles with viscosity < 40 mPas. Here we describe the development of two such ceramic suspensions, which contain up to 30% by volume of PZT particles in either an azeotropic mixture of MEK and ethanol or in an alkane wax at 120 °C. The influence of various processing parameters on fluid rheology are investigated and trial fluids have been passed through an ink-jet printing head.