Ceramic-polymer Composites Research Articles

Synthesis and dielectric characterisation of a low loss BaSrTiO3/ABS ceramic/polymer composite for fused filament fabrication additive manufacturing

Composite polymer/ceramic filaments for material extrusion-based fused filament fabrication additive manufacturing, using barium strontium titanium oxide (BST) ceramics and acrylonitrile butadiene styrene (ABS) thermoplastics were produced; their dielectric and physical properties have been characterised for the first time. The dielectric properties, relative permittivity (ε r ), quality factor ( Q×f ) and dielectric loss (tan δ ) were measured as a function of ceramic solid loading (%) at 5 GHz for 3D printed samples. A relative permittivity ε r = 6.05, Q×f = 10,433 GHz and dielectric loss tan δ = 0.007 were obtained for a BST/ABS ceramic polymer composite, with 50 wt% (15 vol%) solid loading. The composite materials exhibit reduced dielectric losses compared to standard laminates currently used in the radiofrequency (RF) and telecommunications industry. Based on polymer/ceramic composite filament, a prototype microstrip patch 5 G antenna and a hemispherical dielectric lens were designed and manufactured. Through testing, it shows good antenna performance with a centre frequency of f 0 = 3.78 GHz and a (−10 dB) bandwidth of 90.6 MHz. The dielectric lens increased the antenna gain by 3.86 dBi.

Impedance spectroscopy of polymer-ceramic composites

Polymer-ceramic composites from a new class of construction and functional materials of great potential applications in having combined hardness and stiffness of ceramics along with flexibility, elasticity, low density, and higher breakdown strength of polymers and hence are being increasingly harnessed for their specific dielectric, ferroelectric, piezoelectric, piezoelectric, electro-optic, as well as superconducting properties in micro-devices. The charge transport mechanism in polymer-ceramic composites is a longstanding problem. Alternating Current Impedance Spectroscopy (ACIS) is faind to be a valuable experimental tool for the understanding of the phenomenon of the charge transport in micro-and nano composites. Keywords: polymer composite; impedance spectroscopy; polymer; complex resistance; electric field; relaxation time; phase shift angle.

Cold sintering co‐firing of (Ca,Bi)(Mo,V)O4–PTFE composites in a single step

AbstractBecause of large differences in the processing temperature windows between ceramics and polymers, the single‐step co‐sintering of microwave dielectric ceramic–polymer substrates remains challenging. In this work, a dense (Ca0.65Bi0.35)(Mo0.65V0.35)O4 (CBMVO) ceramic was first prepared through cold sintering at 150°C, under a uniaxial pressure of 300 MPa for 60 min with Li2MoO4 (LMO) as a transient low‐temperature solvent. Cold‐sintered CBMVO–5 wt% LMO ceramic shows excellent microwave dielectric properties: εr ∼ 11.4, Q × f ∼ 7070 GHz, τf ∼ −7.4 ppm/°C. Moreover, the optimized cold sintering process enabled the preparation of a layered co‐sintered (2–2 type) CBMVO–polytetrafluoroethylene composite, which maintained excellent microwave dielectric properties and showed a good heterogeneous interface bonding. The proposed cold sintering co‐firing of ceramic–polymer composites in a single step shows great potential for application in the seamless integration between ceramics and polymer substrates.

Influence of (0.19HfO2-0.81ZrO2) ceramics filler content on structural and dielectric properties of PVDF polymer

The rapid evolution of modern technology for the sustainable development of human beings demands eco-friendly, flexible, cost-effective, and lightweight smart materials. Ceramics-polymer composites are those novel materials with improved features, which fulfill the prerequisite conditions for application in flexible devices. Pristine PVDF is one of such electroactive flexible polymers which exhibits good dielectric, ferroelectric and piezoelectric properties. But, its functional properties in the perspective of device application still need improvement and this can be achieved by adding filler to the pure PVDF. In this communication, we have reported the influence of Hafnia-Zirconia (HZ) ceramics (0.19HfO2-0.81ZrO2) filler on structural, microstructural, dielectric, and electrical properties of pure PVDF matrix. The polymer-ceramics flexible composites are synthesized by an eco-friendly and cost-effective method i.e., solution casting method. The phase formation of flexible composites is confirmed from the room temperature XRD spectra. The degree of crystallinity increases with an increase in filler content. The degree of β-phase crystallinity is found to be maximum for 5 wt% of the ceramics filler. An enhanced dielectric constant of ~53 and 20 was observed (as expected) for 5 and 10 wt% of HZ ceramics filler respectively at 100 Hz due to the enrichment of polar β-phase for these two ceramics-polymer composites. The influence of filler content on the dielectric properties was explained based on the percolation model. Relaxation and conduction mechanisms of flexible composites are analyzed from the impedance spectroscopy and ac conductivity study, respectively.

Exploration of free volume behavior and ionic conductivity of PVA: x (x = 0, Y2O3, ZrO2, YSZ) ion-oxide conducting polymer ceramic composites

This article presents a comparative analysis of three distinct zirconia-inserted polyvinyl alcohol (PVA) polymer matrices. X-ray diffraction, Fourier transform infrared spectroscopy (FTIR), and atomic force microscopy (AFM) were used for the study of structural, chemical composition (functional groups), and morphological properties. Changes in IR bands revealed the interaction of nanofillers with the PVA matrix. ZrO2 added sample shows the lowest degree of crystallinity with the least free volume compared to pristine PVA. Threadlike chains and scattershot crystal morphologies were seen in AFM images, and the PVA/ZrO2 has the lowest level of roughness (1.27 nm). Positron annihilation lifetime profile showed identical behavior for τ3, τ2, and their intensities I3,I2. ZrO2 nanoparticles had a better interfacial interaction with the PVA matrix, which resulted in a higher Tg and shorter o-Ps lifetime (τ3). The positron trapping rate increased for ZrO2/PVA polymer ceramic composite (PCC), which indicated that both volume expansion and vacancy trapping effects occur when the positrons are effectively trapped at vacancies. The Nyquist plot for dielectric measurement was investigated, and an equivalent circuit model was used to evaluate variables such as carrier concentration (n), mobility (μ), and diffusion coefficient/ diffusivity (D). Ionic conductivity of 2.77 × 10−7 S cm−1 was recorded for the ZrO2/PVA sample. This might be due to a change (increase) in the carrier concentration.

Combining Solid-State Shear Milling and FFF 3D-Printing Strategy to Fabricate High-Performance Biomimetic Wearable Fish-Scale PVDF-Based Piezoelectric Energy Harvesters.

High-performance flexible piezoelectric polymer-ceramic composites are in high demand for increasing wearable energy-harvesting applications. In this work, a strategy combining solid-state shear milling (S3M) and fused filament fabrication (FFF) 3D-printing technology is proposed for the fabrication of high-performance biomimetic wearable piezoelectric poly(vinylidene fluoride) (PVDF)/tetraphenylphosphonium chloride (TPPC)/barium titanate (BaTiO3) nanocomposite energy harvesters with a biomimetic fish-scale-like metamaterial. The S3M technology could greatly improve the dispersion of BaTiO3 sub-micrometer particles and the interfacial compatibility, resulting in better processability and piezoelectric performance of the nanocomposites. Typically, the FFF 3D printed energy harvester incorporating 30 wt % BaTiO3 showed the highest piezoelectric outputs with an open-circuit voltage of 11.5 V and a short-circuit current of 220 nA. It could hence drive nine green LEDs to work normally. In addition, a 3D-printed biomimetic wearable energy harvester inspired by an environmentally adaptive fish-scale-like metamaterial was further fabricated. The fish-scale-like energy harvester could harvest energy through different deformation motions and successfully recharge a 4.7 μF capacitor by being mounted on a bicycle tire and the tire's rolling. This work not only provides a 3D printing strategy for designing diversified and complex geometric structures but also paves the way for further applications in flexible, wearable, self-powered electromechanical energy harvesters.

3D interpenetrating piezoceramic-polymer composites with high damping and piezoelectricity for impact energy-absorbing and perception

Materials and structures with enhanced energy-absorbing and impact perception capabilities are widely deployed for crash mitigation, protective packaging of sensitive elements, and personal impact protection. However, conventional lightweight structures with a monolithic constitutive material cannot simultaneously achieve exceptional energy-absorbing capacity and electromechanical sensitivity. Here we proposed a new class of architected ceramic-polymer composites with improved energy-absorbing capacity and piezoelectric performance. An interconnected porous lead zirconate titanate ([Pb(Zr 0.52 Ti 0.48 )O 3 ], PZT) skeleton with uniformly distributed cellular-like pores in the transverse section and directionally aligned porous structure in the longitudinal section was fabricated using a facial camphene-templated freeze-casting method. Subsequently, the polymeric polydimethylsiloxane (PDMS) was impregnated into the skeleton to form the three-dimensional (3-D) interpenetrating-phase piezoelectric composite (IP 3 C). The as-fabricated interpenetrating architecture with each phase interconnected has endowed the proposed IP 3 C with an unprecedented combination of mechanical-damping (energy-absorption efficiency ∼ 7.71 MJ m −3 ) and electromechanical-conversion (piezoelectric constant d 33 ∼ 146 pC N −1 ) properties, which are 9 times and 7 times higher than the conventional counterpart 0–3 piezoelectric composite, respectively. As evidenced by numerical simulations, this remarkable enhancement is attributed to the high stress transfer efficiency within the IP 3 C, which is intrinsically controlled by the rationally designed interpenetrating architecture. The findings reported here demonstrate that multifunction, e.g., exceptional energy absorption and high sensitivity, can be achieved in one composite with architecture design, thereby driving forward and expanding the fundamental understanding in the area of multifunctional materials in hostile loading environments. • An interconnected porous lead zirconate titanate ([Pb(Zr 0.52 Ti 0.48 )O 3 ], PZT) skeleton with uniformly distributed cellular-like pores in the transverse section and directionally aligned porous structure in the longitudinal section was fabricated using a facial camphene-templated freeze-casting method. • The as-fabricated interpenetrating architecture with each phase is interconnected has endowed the proposed IP 3 C with an unprecedented combination of mechanical-damping and electromechanical-conversion properties, which are 9 times and 7 times higher than the conventional counterpart 0–3 piezoelectric composite, respectively. • The findings reported here demonstrate that multifunction, e.g., exceptional energy absorption and high sensitivity, can be achieved in one composite with architecture design, thereby driving forward and expanding the fundamental understanding in the area of multifunctional materials in hostile loading environments.

Alkali-Treated Alumina and Zirconia Powders Decorated with Hydroxyapatite for Prospective Biomedical Applications.

The alumina and zirconia surfaces were pretreated with chemical etching using alkaline mixtures of ammonia, hydrogen peroxide and sodium hydroxide, and followed with application of the powder layer of Ca-deficient hydroxyapatite (CDH). The influence of etching bath conditions time and concentration on surface development, chemical composition and morphology of medicinal ceramic powders were studied. The following analyses were performed: morphology (scanning electron microscopy), phase composition (X-ray diffraction analysis), changes in binding interactions and chemical composition (FT-Infrared and Energy dispersive spectroscopies). Both types of etchants did not expose the original phase composition changes or newly created phases for both types of ceramics. Subsequent decoration of the surface with hydroxyapatite revealed differences in the morphological appearance of the layer on both ceramic surfaces. The treated zirconia surface accepted CDH as a flowing layer on the surface, while the alumina was decorated with individual CDH aggregates. The goal of this study was to focus further on the ceramic fillers for polymer-ceramic composites used as a biomaterial in dental prosthetics.

Integration and characterization of a ferroelectric polymer PVDF-TrFE into the grain boundary structure of ZnO via cold sintering

In this study, the Cold Sintering Process (CSP) is used to design ceramic-polymer composites with Polyvinylidene fluoride Trifluoroethylene (PVDF-TrFE), a ferroelectric co-polymer, as an active intergranular grain boundary phase in a semiconducting Zinc Oxide (ZnO) electroceramic matrix. The conductivity is modeled with Schottky thermionic emission and Fowler-Nordheim tunneling as a function of both temperature and voltage. In addition, through details of the dielectric characterization, the interfaces are also considered with the effective permittivity resulting with a space charge relaxation of the PVDF-TrFE. The Maxwell-Wagner-Sillars (MWS) model was used to predict ~ 3 nm as the thickness of the intergranular PVDF-TrFE phase controlling electrical properties of the composite. Transmission electron microscopy (TEM) investigation of the grain boundary phase confirms the polymer thicknesses to the dimensions predicted from the various electric measurements and subsequent modeling.

Enhanced piezoelectric performance of ceramic-polymer composite cantilevers with thin metal substrates

In this work, the electromechanical properties of a lead zirconate titanate-poly(vinylidenefluoride-trifluoroethylene) ceramic-polymer composite on thin brass and steel substrates were investigated. Samples were stencil printed on metal foils and cured at 120 °C. The effective transverse piezoelectric coefficient (d31eff) was calculated by utilizing the converse piezoelectric effect and measuring the displacement of a cantilever sample’s tip in an electric field. Interestingly, the results showed improved piezoelectric properties with the stiffer steel substrate samples. The highest d31eff achieved was about −22 pm/V, which was 29% higher than in samples printed on brass foil (−17 pm/V). Both are substantially higher compared to the coefficients reported with similar ceramic-polymer composites on polymer substrates. The improvement is suggested to originate from the prevention of buckling effects and more effective bending deformation, while the structure remained flexible. Due to the high effective values of d31 and g31, the developed material and cantilever structures are feasible for both sensor and energy harvesting applications.

Obtaining Greatly Improved Dielectric Constant in BaTiO3-Epoxy Composites with Low Ceramic Volume Fraction by Enhancing the Connectivity of Ceramic Phase.

Ceramic-polymer dielectric composites show promising potential as embedded capacitors, whereas it is a great challenge to obtain a high dielectric constant (εr) at a low ceramic volume fraction (Vc). This work demonstrates a strategy for overcoming this challange. By employing a high sintering temperature (Ts) and introducing porogen, BaTiO3 ceramics with both great connectivity and high porosity are obtained, and the composites with improved εr at a low Vc are prepared after curing the epoxy monomer, which is infiltrated into the porous ceramic bodies. For the composite with a Ts of 1300 °C and a Vc of 38.1%, the εr is as high as 466.8 at 1 kHz, which is improved by about nine times compared to the 0-3 counterpart with a higher Vc of 60.8%. Furthermore, the composite exhibits low dielectric loss and good frequency and temperature stability of εr, indicating the great potential for practical applications. Finite element simulation shows that the enhanced connectivity of BaTiO3 increases the electric field intensity in high-εr BaTiO3 dramatically and therefore plays a key role in the dielectric response of the composite. This work not only sheds light on the high-εr ceramic-polymer composites but also deepens the understanding on the relationship between their properties and microstructures.

Interface failure and delamination resistance of fiber-reinforced geopolymer composite by simulation and experimental method

Fiber-reinforced geopolymer matrix composites (FRGC) have the potential areas of application to bridge the gap between the performances of polymer matrix and ceramic matrix composites. One of the major drawbacks of the geopolymer matrix is the extreme brittleness and weak interlaminar strength. To improve the interlaminar strength of composites, reinforcement of fibers such as carbon and E-glass are considered as fillers in the matrix. The study aimed to evaluate the inner strength and delamination behavior of carbon and E-glass fiber-reinforced composite. The inner structure of the delaminated area of the impacted composite is examined based on the microstructural images and internal areas. The study is being evaluated by simulation method and experimental observation was correlated. The effect of fiber reinforcement was evaluated using three-point flexural methods to obtain strength and modulus of rupture. Results indicate that the interlaminar strength of carbon fiber reinforced geopolymer composite is stronger than E-glass fiber-reinforced composite. The fibers are more intact in carbon fiber reinforced geopolymer composite with better delamination resistance and less impact area. However interlaminar strength of E-glass fiber reinforced is weak, leads to less delamination resistance, with more slippery behavior and more damage area.

3D printed 0–3 type piezoelectric composites with high voltage sensitivity

Piezoelectric composites made of piezoelectric ceramic particles and polymer composites combine the performance advantages of both components and have broad application prospects. However, the preparation of complex structures is still a challenge, for which 3D printing technology provides a perfect solution. The aim of the present study is to investigate the principle and process optimization of the stereolithography of 0–3 type piezoelectric composites through simulation and experiments. In particular, a modified three-phase model of a spherical shell is applied to elucidate the influence of the elastic modulus between the ceramic particles and the matrix on the piezoelectric properties of the composites at the macroscopic level. This enables the piezoelectric properties of the composites to be predicted more accurately, and guides the surface grafting modification of piezoelectric ceramic powders. Furthermore, the problem of weak interface bonding in piezoelectric composites caused by poor compatibility between hydrophilic particles and the hydrophobic matrix is successfully solved by preprocessing the PZT ceramic powder via activating the particle surface hydroxyl groups and grafting a silane coupling agent onto the piezoelectric ceramic powder. As a result, the particles are bonded to the matrix by covalent bonds, which increases the elastic modulus of the interface transition layer and modifies the stress transfer efficiency. For instance, the piezoelectric strain constant (d33) of piezoelectric composite containing 60 wt% functionalized PZT particles is increased from 20 to 37 pC/N. The printing accuracy, piezoelectric properties, and mechanical characteristics of the piezoelectric composites are thoroughly investigated, and the reliability of the proposed theoretical model and simulation results is verified. The piezoelectric composites are uniformly compact and have a low residual pore rate. The piezoelectric composite with a solid content of 60 wt% has a volume density of 2.27 g/cm3 and a Young's modulus of 535.44 MPa. Most importantly, its piezoelectric voltage constant (g33) is 167.2 × 10−3 Vm/N, which is more than seven times higher than that of homogeneous PZT and results in high voltage sensitivity.

Improved thermal conductivity of ceramic-epoxy composites by constructing vertically aligned nanoflower-like AlN network

Ceramic-polymer composites with good thermal conductivity, low dielectric constant and low dielectric loss have significant applicability in microelectronics and wireless communication systems. However, traditional thermal conductivity ceramic-polymer composites – realized simply through the random dispersion of spherical or near-spherical ceramic powder fillers – cannot have both high thermal conductivity and good electrical insulation, which greatly hinders their practical application. In this study, we first used metallic Al powder corroded by ultrasonic cavitation as the aluminium source, and then prepared spherical aluminium nitride (AlN) powders with many nano petals grown on the surface using the melamine-assisted nitriding method; subsequently, the ice-template method was utilized to construct a three-dimensional (3D) AlN framework with vertical columnar holes, and finally, nanoflower-like AlN-epoxy (EP) composites were prepared by vacuum infiltration. The unique nano petal structures on the surface of AlN powder and the welding between AlN nano-petals during vacuum sintering increased the contact area between nanoflower-like AlN powders and lowered their contact thermal resistance. Moreover, the construction of vertical AlN channels was conducive to the formtion of thermally conductive pathways in AlN-epoxy composites. As a result, we obtained ceramic-polymer composites with improved thermal conductivity, among which the composites with 20 vol% nanoflower-like AlN powder had the highest thermal conductivity – 2.26 W/m·K – compared to a pure matrix, which is equivalent to an enhancement of 830%.

In Situ Printing and Functionalization of Hybrid Polymer-Ceramic Composites Using a Commercial 3D Printer and Dielectrophoresis-A Novel Conceptual Design.

Three-dimensional printing-based additive manufacturing has emerged as a new frontier in materials science, with applications in the production of functionalized polymeric-based hybrid composites for various applications. In this work, a novel conceptual design was conceived in which an AC electric field was integrated into a commercial 3D printer (-based fused filament fabrication (FFF) working principle) to in situ manufacture hybrid composites having aligned ceramic filler particles. For this work, the thermoplastic poly lactic acid (PLA) was used as a polymer matrix while 10 vol% KNLN (K0.485Na0.485Li0.03NbO3) ceramic particles were chosen as a filler material. The degree of alignment of the ceramic powders depended upon print speed, printing temperature and distance between electrodes. At 210 °C and a 1 kV/mm applied electric field, printed samples showed nearly complete alignment of ceramic particles in the PLA matrix. This research shows that incorporating electric field sources into 3D printing processes would result in in situ ceramic particle alignment while preserving the other benefits of 3D printing.

Rheological and Technological Aspects in Designing the Properties of Shear Thickening Fluids.

This work focuses on shear thickening fluids (STFs) as ceramic–polymer composites with outstanding protective properties. The investigation aims to determine the influence of raw material parameters on the functional properties of STFs. The following analyses were used to characterize both the raw materials and the STFs: scanning electron microscopy, dynamic light scattering, matrix-assisted laser desorption/ionization time-of-flight, chemical sorption analysis, rheological analysis, and kinetic energy dissipation tests. It was confirmed that the morphology of the solid particles plays a key role in designing the rheological and protective properties of STFs. In the case of irregular silica, shear thickening properties can be obtained from a solid content of 12.5 vol.%. For spherical silica, the limit for achieving shear thickening behavior is 40 vol.%. The viscosity curve analysis allowed for the introduction of a new parameter defining the functional properties of STFs: the technological critical shear rate. The ability of STFs to dissipate kinetic energy was determined using a unique device that allows pure fluids to be tested without prior encapsulation. Because of this, it was possible to observe even slight differences in the protective properties between different STFs, which has not been possible so far. During tests with an energy of 50 J, the dissipation factor was over 96%.

Polyvinylidene fluoride – Hydroxyapatite 0–3 biocomposite filaments processed by twin-screw extrusion

Polyvinylidene fluoride – hydroxyapatite composite filaments were processed by twin-screw extrusion at different processing angular velocities and characterized by scanning electron and atomic force microscopies, differential scanning calorimetry and tensile tests. Polymer-ceramic composites with a 0–3 connectivity were successfully obtained. Regardless of the used processing parameters, all composite filaments present very similar melting (∼152°C) and solidification (∼139°C) points and elastic moduli (∼1.0 GPa) for hydroxyapatite as dispersed phase in the composite with concentrations up to 25 wt%, indicating that they are adequate for twin-screw extrusion and 3D printing. However, the yield strength (∼29 MPa), ultimate tensile strength (∼36 MPa) and tensile point (∼29 MPa) parameters are similar only for hydroxyapatite concentrations up to 15 wt%, once higher concentrations of hydroxyapatite as dispersed phase result in fragile samples (∼50% lower for each studied property).

Preparation, Characterization, and Biocompatibility Assessment of Polymer-Ceramic Composites Loaded with Salvia officinalis Extract.

In the present work, hydroxyapatite-polymer materials were developed. The preparation, as well as characterization of the ceramic-polymer composites based on polyvinylpyrrolidone, sodium alginate, and gelatin were described. The system was enriched with the addition of common sage extract (Salvia officinalis). The antioxidant potential of sage aqueous extract and total polyphenol content was determined. The antioxidant capacity and total phenolic content of extract were equal to 86.06 ± 0.49% and 16.21 ± 0.58 mg gallic acid equivalents per gram of dry weight, respectively. Incubation studies in selected biological liquids were carried out to determine the biomineralization capacity on the surface of the composites and to examine the kinetics of release of the active substances from within the material. As a result of the incubation, a gradual release of the extract over time from the polymer matrix was observed; moreover, the appearance of new apatite layers on the composite surface was recorded as early as after 14 days, which was also confirmed by energy-dispersive X-ray spectroscopy (EDS) microanalysis. The composites were analyzed with Fourier transform infrared spectroscopy (FTIR) spectroscopy, and the morphology was recorded by scanning electron microscope (SEM) imaging. The in vitro biological studies allowed their cytotoxic effect on the reference L929 fibroblasts to be excluded. Further analysis of the biomaterials showed that enrichment with polyphenols does not support the adhesion of L929 cells to the surface of the material. However, the addition of these natural components stimulates human monocytes that constitute the first step of tissue regeneration.

Formulation of a Ceramic Ink for 3D Inkjet Printing.

Due to its multi-material capabilities, 3D inkjet printing allows for the fabrication of components with functional elements which may significantly reduce the production steps. The potential to print electronics requires jettable polymer-ceramic composites for thermal management. In this study, a respective material was formulated by functionalizing submicron alumina particles by 3-(trimethoxysilyl)propylmethacrylate (MPS) and suspending them in a mixture of the oligourethane Genomer 4247 with two acrylate functionalities and a volatile solvent. Ink jetting tests were performed, as well as thermal conductance and mechanical property measurements. The material met the strict requirements of the printing technology, showing viscosities of around 16 mPa·s as a liquid. After solidification, it exhibited a ceramic content of 50 vol%, with a thermal conductance of 1 W/(m·K). The resulting values reflect the physical possibilities within the frame of the allowed tolerances set by the production method.

Cold Sintering of PZT 2-2 Composites for High Frequency Ultrasound Transducer Arrays

Medical ultrasound and other devices that require transducer arrays are difficult to manufacture, particularly for high frequency devices (>30 MHz). To enable focusing and beam steering, it is necessary to reduce the center-to-center element spacing to half of the acoustic wavelength. Conventional methodologies prevent co-sintering ceramic–polymer composites due to the low decomposition temperatures of the polymer. Moreover, for ultrasound transducer arrays exceeding 30 MHz, methods such as dice-and-fill cannot provide the dimensional tolerances required. Other techniques in which the ceramic is formed in the green state often fail to retain the required dimensions without distortion on firing the ceramic. This paper explores the use of the cold sintering process to produce dense lead zirconate titanate (PZT) ceramics for application in high frequency transducer arrays. PZT–polymer 2-2 composites were fabricated by cold sintering tape cast PZT with Pb nitrate as a sintering aid and ZnO as the sacrificial layer. PZT beams of 35 μm width with ~5.4 μm kerfs were produced by this technique. The ZnO sacrificial layer was also found to serve as a liquid phase sintering aid that led to grain growth in adjacent PZT. This composite produced resonance frequencies of >17 MHz.