Fabrication of high-performance MgTiO3–CaTiO3 microwave ceramics through a stereolithography-based 3D printing

Abstract

The potential of 3D printing to prepare ceramic RF devices is investigated. (1–x)MgTiO3–xCaTiO3 ceramics (x = 0, 0.1, 0.2, and 0.4) are prepared by 3D printing and subsequent sintering. MgTiO3 and CaTiO3, synthesized by conventional solid-state method, are initially dispersed in ultraviolet-curable resins with appropriate dispersant and photoinitiator. After subjecting the printed samples to debinding and sintering, their density, phase composition, microstructure, and microwave characteristic are measured. Calcined powders of (1–x)MgTiO3–xCaTiO3 ceramics are found to maintain a high solid content (up to 80 wt%) in the resin while maintaining reasonable viscosity values. Moreover, the ultraviolet absorptivity of ceramic is a key factor influencing curing depth. The 3D-printed samples also have the same phase composition, higher density, more uniform particle size, and better microwave performance than dry-pressed samples. Finally, a flat Luneburg lens antenna with MgTiO3–CaTiO3 ceramic is realized using Stereolithography. This work helps to promote research on 3D-printed microwave ceramics and the fabrication of complex RF ceramic devices.