Hot moulding of zirconia micro parts

Zirconia micro parts were fabricated by a sequence of process steps. A master model (a positive to the final ceramic part) was copied into a silicone rubber mould insert and the rubber mould insert was used for producing ZrO₂ prototypes by hot moulding. Hot moulding was carried out with suspensions of ZrO₂ in a mixture of paraffin and a dispersant. The rheological properties of different commercial ZrO₂ powders were tested with respect to their hot moulding application. A different sequence of process steps was developed to be able to start with a negative and to fabricate the ceramic micro parts as positives. This sequence included as a final step that the hot-moulding feedstock was filled into a mould insert which consisted of an organic material. Debinding was carried out without prior separation of the green body and the mould insert (lost mould technique).