Purpose: Conventional machining methods for fabricating piezoelectric components such as ultrasound transducer arrays are time-consuming and limited to relatively simple geometries. The purpose of this paper is to develop an additive manufacturing process based on the projection-based stereolithography process for the fabrication of functional piezoelectric devices including ultrasound transducers. Design/methodology/approach: To overcome the challenges in fabricating viscous and low-photosensitive piezocomposite slurry, the authors developed a projection-based stereolithography process by integrating slurry tape-casting and a sliding motion design. Both green-part fabrication and post-processing processes were studied. A prototype system based on the new manufacturing process was developed for the fabrication of green-parts with complex shapes and small features. The challenges in the sintering process to achieve desired functionality were also discussed. Findings: The presented additive manufacturing process can achieve relatively dense piezoelectric components (approximately 95 per cent). The related property testing results, including X-ray diffraction, scanning electron microscope, dielectric and ferroelectric properties as well as pulse-echo testing, show that the fabricated piezo-components have good potentials to be used in ultrasound transducers and other sensors/actuators. Originality/value: A novel bottom-up projection system integrated with tape casting is presented to address the challenges in the piezo-composite fabrication, including small curing depth and viscous ceramic slurry recoating. Compared with other additive manufacturing processes, this method can achieve a thin recoating layer (as small as 10 μm) of piezo-composite slurry and can fabricate green parts using slurries with significantly higher solid loadings. After post processing, the fabricated piezoelectric components become dense and functional.

Piezoelectric arrays are widely used in non-destructive detecting, medical imaging and therapy. However, limited by traditional manufacturing methods, the array’s element is usually designed in simple geometry such as a cube or rectangle, restricting potential applications of the array. This work demonstrates an annular piezoelectric array consisting of different concentric elements printed by Mask-Image-Projection-based Stereolithography (MIP-SL) technology. The printed array displays stable piezoelectric and dielectric properties. Compared to a traditional single element transducer, the ultrasonic transducer with printed array successfully modifies the acoustic beam and significantly improves spatial resolution.

Porous structure has wide application in industry due to some of its unique properties such as low density, low thermal conductivity, high surface area, and efficient stress transmission. Both templating and foaming agent methods have been used to fabricate porous structures. However, these methods can only fabricate simple geometries. In recent years, many studies have been done to use additive manufacturing (AM), e.g., stereolithography apparatus (SLA), in the fabrication of porous structure; however, the porosity that can be achieved is relatively small due to the limited accuracy in building microscale features on a large area. This paper presents a projection-based SLA process to fabricate porous polymer structures using sugar particles as the foaming agent. With a solid loading of 50 wt.% of sugar in photocurable resin, the method can achieve a structure with much higher porosity. As shown in our results, the method can increase the porosity of fabricated scaffold structures by two times when compared to the current SLA method.

An additive manufacturing-enabled bi-continuous piezocomposite architecture is presented to achieve mechanical flexibility and piezoelectricity simultaneously in piezoelectric materials. This architecture comprises an active ferroelectric ceramic phase and a passive flexible polymer phase, which are separated by a tailorable phase interface. Triply periodic minimal surfaces were used to define the phase interface, due to their excellent elastic properties and load transfer efficiency. A suspension-enclosing projection-stereolithography process was used to additively manufacture this material. Postprocesses including polymer infiltration, electroding, and poling are introduced. Piezoelectric properties of the piezocomposites are numerically and experimentally studied. The results highlight the role of tailorable triply periodic phase interfaces in promoting mechanical flexibility and piezoelectricity of bi-continuous piezocomposites.