Piezoelectric composites are considered excellent core materials for fabricating various ultrasonic devices. For the traditional fabrication process, piezoelectric composite structures are mainly prepared by mold forming, mixing, and dicing-filing techniques. However, these techniques are limited on fabricating shapes with complex structures. With the rapid development of additive manufacturing (AM), many research fields have applied AM technology to produce functional materials with various geometric shapes. In this study, the Mask-Image-Projection-based Stereolithography (MIP-SL) process, one of the AM (3D-printing) methods, was used to build BaTiO₃-based piezoelectric composite ceramics with honeycomb structure design. A sintered sample with denser body and higher density was achieved (i.e., density obtained 5.96 g/cm³), and the 3D-printed ceramic displayed the expected piezoelectric and ferroelectric properties using the complex structure (i.e., piezoelectric constant achieved 60 pC/N). After being integrated into an ultrasonic device, the 3D-printed component also presents promising material performance and output power properties for ultrasound sensing (i.e., output voltage reached 180 mVpp). Our study demonstrated the effectiveness of AM technology in fabricating piezoelectric composites with complex structures that cannot be fabricated by dicing-filling. The approach may bring more possibilities to the fabrication of micro-electromechanical system (MEMS)-based ultrasonic devices via 3D-printing methods in the future.

Acoustic tweezers for microparticle non-contact manipulation have attracted attention in the biomedical engineering field. The key components of acoustic tweezers are piezoelectric materials, which convert electrical energy to mechanical energy. The most widely used piezoelectric materials are lead-based materials. Because of the requirement of environmental protection, lead-free piezoelectric materials have been widely researched in past years. In our previous work, textured lead-free (K, Na)NbO₃ (KNN)-based piezoelectric ceramics with high piezoelectric performance were prepared. In addition, the acoustic impedance of the KNN-based ceramics is lower than that of lead-based materials. The low acoustic impedance could improve the transmission efficiency of the mechanical energy between acoustic tweezers and water. In this work, acoustic tweezers were prepared to fill the gap between lead-free piezoelectric materials research and applications. The tweezers achieved 13 MHz center frequency and 89% −6 dB bandwidth. The −6 dB lateral and axial resolution of the tweezers were 195 μm and 114 μm, respectively. Furthermore, the map of acoustic pressure measurement and acoustic radiation calculation for the tweezers supported the trapping behavior for 100 μm diameter polystyrene microspheres. Moreover, the trapping and manipulation of the microspheres was achieved. These results suggest that the KNN-based acoustic tweezers have a great potential for further applications.

Lead-free piezoelectric 0.92(K_0.445Na_0.5Li_0.05)NbO₃-0.08BaZrO₃ (KNLN-BZ) ceramics were prepared via conventional sintering. Single-step, 2-step and 3-step temperature-controlled conditions were designed. The structure and electrical properties of ceramics obtained using different temperature-controlled procedures were systematically studied. It was found that ceramic prepared using the 3-step method with a holding time of 20 h showed the highest electrical properties. The Curie temperature was approximately 286 °C, and the dielectric constant and dielectric loss at room temperature were 1350 and 4.5% at the frequency of 1 kHz, respectively. The highest remanent polarization, piezoelectric strain and piezoelectric coefficient, d₃₃*, were obtained 60 °C, indicating a phase transition between ferroelectric phases. Although the ceramics did not show excellent piezoelectric properties, the 3-step sintering method can be considered an effective method to optimize the electrical performances of KNN-based ceramics. Combined with an appropriate composition, ceramics with excellent electrical properties could be obtained. This study provides a path to enhance the density and electrical properties for KNN-based ceramics with simple composition and potential for industry application.