Effect of the polystyrene particle size on dielectric and piezoelectric properties of PZT piezoelectric ceramics via vat photopolymerization (VPP)

The fabrication of lead zirconate titanate (PZT) ceramics using VPP technology presents a significant challenge due to the suboptimal curing performance and printability of PZT ceramic slurry. In this study, we successfully manufactured PZT ceramics utilizing vat photopolymerization (VPP) technology by incorporating polystyrene (PS) powders of varying particle sizes into the PZT ceramic slurries. Our investigation revealed that the incorporation of PS powders dramatically enhances the curing performance of the PZT slurry. Furthermore, it was found that the electrical properties of resultant ceramics are intrinsically linked to the morphology and dimensions of the induced pores. However, our research findings indicate that an excessive particle size of PS can negatively impact the dielectric and piezoelectric properties of the PZT ceramics, underscoring the need for careful control over PS powder size during fabrication. The pronounced discrepancy in particle size between PZT and PS powders may lead to suboptimal interlayer combination within specific regions of the green body. Consequently, this could render the PZT ceramics susceptible to additional defect formation. Nonetheless, the fabricated PZT piezoelectric ceramics with a PS particle size of 3 µm demonstrate exceptional electrical characteristics. This research proposes a straightforward and productive approach for broadening the spectrum of processable ceramics within the domain of VPP technology, while offering a comprehensive understanding of the influence exerted by the morphology and dimension of pores on dielectric and piezoelectric properties of ceramic materials.