Completed: Circularising the Pressure Moulding of Ceramics

In collaboration with PCL Ceramics and Dr. Ozge Akbulut, Sabancı University, Istanbul

In this project, we showcased an innovative way of processing ceramics in the dough form that is ideal for pressure-moulding (e.g., ram pressing and injection moulding) at room temperature with a minimum required pressure (hand pressing). The process involved the incorporation of a single copolymer additive at a minimum amount to induce polymer bridging consequently obtain a self-standing, malleable dough structure. The stamping experiment showed that the pattern on the stamp is flawlessly copied onto the ceramic dough when the stamp is lifted. The dough formulation required little pressure, making it cost-effective and energy efficient. Additionally, a different formulation was developed for injection moulding that had lower viscosity. This formulation was intentionally made to be non-malleable, yet injectable.

The resulting density of the sintered materials was measured to be 96.7% of the theoretical density, indicating a high level of densification and minimal porosity. Flexural strength of 172 MPa was obtained, using a three-point bending standard C1161-13.

This new processing method has significant potential to facilitate the production of intricate and complex shapes without compromising the mechanical integrity of the materials. It offers several advantages over traditional casting methods, including increased productivity as well as reductions in the equipment cost, amount of chemicals, and CO₂ emissions. The successful demonstration of the two moulding ability will facilitate development of advanced ceramics for tailored applications according to industry needs. Furthermore, we have carried out an environmental impact assessment study to provide a valuable insight, primarily for our industrial partner, which can be applied to different product development stages in the ceramics industry. Our analysis clearly indicates that our approach can contribute to the Ceramics Innovation Network’s carbon-net-zero aims, demonstrating the potential for significant positive impact.

Dr. Ahu Gumrah Dumanli-Parry ahugumrah.parry@manchester.ac.uk

University of Manchester