Fabrication of high-performance MgTiO3-CaTiO3 microwave ceramics through a stereolithography-based 3D printing

The potential of 3D printing to prepare ceramic RF devices is investigated. (1-x)MgTiO3-xCaTiO(3) ceramics (x = 0, 0.1, 0.2, and 0.4) are prepared by 3D printing and subsequent sintering. MgTiO3 and CaTiO3, synthesized by conventional solid-state method, are initially dispersed in ultraviolet-curable resins with appropriate dispersant and photoinitiator. After subjecting the printed samples to debinding and sintering, their density, phase composition, microstructure, and microwave characteristic are measured. Calcined powders of (1-x) MgTiO3-xCaTiO(3) ceramics are found to maintain a high solid content (up to 80 wt%) in the resin while maintaining reasonable viscosity values. Moreover, the ultraviolet absorptivity of ceramic is a key factor influencing curing depth. The 3D-printed samples also have the same phase composition, higher density, more uniform particle size, and better microwave performance than dry-pressed samples. Finally, a flat Luneburg lens antenna with MgTiO3-CaTiO3 ceramic is realized using Stereolithography. This work helps to promote research on 3D-printed microwave ceramics and the fabrication of complex RF ceramic devices.