Techniques are currently being developed to allow complex shapes to be created directly from a computer program by the addition of material to, rather than the abstraction of material from, the component. These are mouldless manufacturing operations, variously known as solid free-form fabrication [1,2], rapid prototyping [3] or, more colloquially, "art to part" technology [4, 5]. Various materials processing operations have been adapted for this purpose. In laminated object manufacture (LOM), laser-cut layers of foil are stacked to produce the shape [5]. In stereolithography, an ultraviolet (UV) laser is used to scan and cure a photosensitive monomer [6]. In selective laser sintering, a more powerful laser is used to scan and sinter a deposit of ceramic, metal or polymer powder [1, 7]. Although the last process is attractive for ceramics manufacture, considerable problems of particle packing before sintering and of residual stresses set up during sintefing remain. So far, the main practical use of these techniques is the rapid creation of a prototype from a computer program, but the longer term possibilities for ceramics include the manufacture of high resolution mulfilayer circuits and devices, the fabrication of solid oxide fuel cells of complex design, the preparation of ordered ceramic composites for structural or piezoelectric applications and the manufacture of highly complex small monolithic ceramics. Previous work at Brunel University has considered manufacturing operations for ceramics in which the powder is dispersed in an organic vehicle [8, 9]. These processes do not depend on agglomerated powders and have the capability to achieve the excellent dispersion necessary for high performance ceramics [10]. Similar requirements are applicable in paint and printing operations. Recent work has shown that the random deposition of droplets of a ceramic paint can be used to produce multilayer ceramic composites [11]. Although many printing operations are used in the traditional ceramics industry, only screen printing is widely used for advanced ceramics. Jet printing [12] is a non-contact printing process in which small ( 5 × 10-13m 3) drops of ink are ejected when required from a thermal or piezoelectric activated nozzle of diameter 25-75/xm (drop on demand ink jet printing). In contrast, continuous ink jet printing uses charged drops from a continuously recycled stream, which are diverted to the substrate when required by a voltage applied to deflector plates. Ink jet technology has been used to deposit a binder solution on to layers of roll-compacted ceramic powder to fix particles in place before conventional sintering [13]. This allows the creation of a porous ceramic by computer aided manufacture (CAM). A ceramic ink was prepared by selecting a thermoplastic resin, dispersant and ceramic powder such that the ceramic occupied 60 vol% in the absence of solvent. This volume fraction was chosen to avoid shrinkage cracks [11]. It also confers thermoplastic properties to the dried ink to allow subsequent plastic forming operations if required. This composition was diluted with solvent for printing. The sources of materials and composition of the ink are given in Table I. The polyvinyl butyral
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