Process chain development for the realization of zirconia microparts using composite reaction molding

Composite reaction molding as rapid prototyping technique using polymer-based reactive resins and suitable inorganic fillers enables the realization of ceramic parts carrying a microstructured surface relief. In this paper the development of the whole process chain starting with feedstock preparation and characterization, molding and thermal postprocessing like debinding and sintering will be described for the fabrication of dense zirconia parts. Especially the rheological behaviour as function of the binder composition and solid load is discussed intensely. Specific feedstock parameters like critical filler load and flow activation energy are derived from the measured flow properties using empirical descriptions normally applied for feedstock systems established in powder injection molding.