Abstract
A direct‐foaming technique to produce macro‐porous ceramics is presented considering three key aspects: (i) a processing route without toxic additives, (ii) optimizing particle packing and dispersion of ceramic suspensions to obtain denser struts, and (iii) processing reliability for large‐scale production. To achieve the latter goal, specific foaming equipment was designed. Ceramics with large dimensions (250 × 60 × 110 mm3), high porosity level (>70%), homogeneous and narrower pore‐size distribution, high Weibull modulus (8 to 11), improved mechanical strength (3 to 15 MPa) for different compositions and low thermal conductivity at 1200°C (0.3 to 0.9 W/mK) were attained.
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