\"This research focuses on the processing of novel feedstocks for and during direct-write additive manufacturing (AM), specifically the direct ink writing (DIW) and Ceramic On-Demand Extrusion (CODE) manufacturing processes, in order to produce ceramic and ceramic-based composite components. Strongly dispersed, concentrated (φ = 0.42), nanoparticle (d50 ~0.3 µm), zirconia (ZrO2) pastes were used to print densely filled, large continuous volume (≳ 1 cm3) ceramic components. An elastic shear modulus (G’) of 56,000 Pa and yield stresses between 6 and 10 Pa allowed for printed components of 34.5 mm in height over 115 layers without slumping due to partial drying. Printed parts exhibited lateral particle migration during post-processing. Several methods were proposed to improve future feedstocks to prevent this defect. A zirconium diboride (ZrB2) paste (φ = 0.45) was formulated to print fine-featured (<335 >µm), ultra-high temperature ceramic (UHTC) monoliths. The final ZrB2-based paste exhibited an elastic shear modulus of ~104 Pa, flow index of 0.34, and flow stress of ~40 Pa, as-designed for monolithic printing. In discrete multi-material printing, dielectric and conductor formulations were printed together to established considerations for co-DIW of ceramic electronic packaging technologies. Low temperature co-fired ceramic (LTCC) structures were demonstrated by co-printing but were not successfully post-processed due to mismatched co-drying. In graded printing, a Mo (φ = 0.45) paste was developed to print with ZrB2. These formulations were successfully combined to 3D print 11 layer, 10% gradings between the constituents into laminar bars. These bars were pressurelessly sintered to 2050°C without observed cracking but had an average warpage of 20 ± 9°\"--Abstract, p. iv
","abstract_html":"<p>"This research focuses on the processing of novel feedstocks for and during direct-write additive manufacturing (AM), specifically the direct ink writing (DIW) and Ceramic On-Demand Extrusion (CODE) manufacturing processes, in order to produce ceramic and ceramic-based composite components. Strongly dispersed, concentrated (φ = 0.42), nanoparticle (d<sub>50</sub> ~0.3 µm), zirconia (ZrO<sub>2</sub>) pastes were used to print densely filled, large continuous volume (≳ 1 cm<sup>3</sup>) ceramic components. An elastic shear modulus (G’) of 56,000 Pa and yield stresses between 6 and 10 Pa allowed for printed components of 34.5 mm in height over 115 layers without slumping due to partial drying. Printed parts exhibited lateral particle migration during post-processing. Several methods were proposed to improve future feedstocks to prevent this defect. A zirconium diboride (ZrB<sub>2</sub>) paste (φ = 0.45) was formulated to print fine-featured (<335 >µm), ultra-high temperature ceramic (UHTC) monoliths. The final ZrB<sub>2</sub>-based paste exhibited an elastic shear modulus of ~10<sup>4</sup> Pa, flow index of 0.34, and flow stress of ~40 Pa, as-designed for monolithic printing. In discrete multi-material printing, dielectric and conductor formulations were printed together to established considerations for co-DIW of ceramic electronic packaging technologies. Low temperature co-fired ceramic (LTCC) structures were demonstrated by co-printing but were not successfully post-processed due to mismatched co-drying. In graded printing, a Mo (φ = 0.45) paste was developed to print with ZrB<sub>2</sub>. These formulations were successfully combined to 3D print 11 layer, 10% gradings between the constituents into laminar bars. These bars were pressurelessly sintered to 2050°C without observed cracking but had an average warpage of 20 ± 9°"--Abstract, p. iv</p>","abstract_has_math":false,"creators":["Martin, Austin"],"institution":"Missouri University of Science and Technology","degree_name":"Ph. D. in Materials Science and Engineering","degree_level":null,"degree_discipline":null,"degree_department":null,"school":null,"contributors":[],"advisors":[],"committee_chairs":[],"committee_members":[],"year":null,"date_issued":"","date_published":null,"updated_at":"2026-07-24T03:18:18Z","subjects":["Additive manufacturing","Direct ink write","Functionally graded materials","Low temperature co-fired ceramics","Robocasting","Ultra-high temperature ceramics","Materials Science and Engineering"],"languages":[],"rights":[],"rights_urls":[],"identifier_entries":[]},"links":{"outbound_url":"https://scholarsmine.mst.edu/doctoral_dissertations/3215","outbound_label":"Repository record","outbound_source":"dc:identifier"},"metadata_groups":[{"id":"people","label":"People","entries":[{"key":"dc:creator","label":"Author","values":["Martin, Austin"]}]},{"id":"academic_context","label":"Academic Context","entries":[{"key":"dc:type","label":"Dc Type","values":["Dissertation - Open Access"]},{"key":"thesis:degree_name","label":"Degree Name","values":["Ph. D. in Materials Science and Engineering"]},{"key":"thesis:institution_name","label":"Thesis Institution Name","values":["Missouri University of Science and Technology"]}]},{"id":"subjects_keywords","label":"Subjects and Keywords","entries":[{"key":"dc:subject","label":"Dc Subject","values":["Additive manufacturing","Direct ink write","Functionally graded materials","Low temperature co-fired ceramics","Robocasting","Ultra-high temperature ceramics","Materials Science and Engineering"]}]},{"id":"identifiers","label":"Identifiers","entries":[{"key":"dc:identifier","label":"Identifier","values":["https://scholarsmine.mst.edu/doctoral_dissertations/3215"]}]},{"id":"additional","label":"Additional Metadata","entries":[{"key":"dc:description.abstract","label":"Abstract","values":["\"This research focuses on the processing of novel feedstocks for and during direct-write additive manufacturing (AM), specifically the direct ink writing (DIW) and Ceramic On-Demand Extrusion (CODE) manufacturing processes, in order to produce ceramic and ceramic-based composite components. Strongly dispersed, concentrated (φ = 0.42), nanoparticle (d50 ~0.3 µm), zirconia (ZrO2) pastes were used to print densely filled, large continuous volume (≳ 1 cm3) ceramic components. An elastic shear modulus (G’) of 56,000 Pa and yield stresses between 6 and 10 Pa allowed for printed components of 34.5 mm in height over 115 layers without slumping due to partial drying. Printed parts exhibited lateral particle migration during post-processing. Several methods were proposed to improve future feedstocks to prevent this defect. A zirconium diboride (ZrB2) paste (φ = 0.45) was formulated to print fine-featured (<335 >µm), ultra-high temperature ceramic (UHTC) monoliths. The final ZrB2-based paste exhibited an elastic shear modulus of ~104 Pa, flow index of 0.34, and flow stress of ~40 Pa, as-designed for monolithic printing. In discrete multi-material printing, dielectric and conductor formulations were printed together to established considerations for co-DIW of ceramic electronic packaging technologies. Low temperature co-fired ceramic (LTCC) structures were demonstrated by co-printing but were not successfully post-processed due to mismatched co-drying. In graded printing, a Mo (φ = 0.45) paste was developed to print with ZrB2. These formulations were successfully combined to 3D print 11 layer, 10% gradings between the constituents into laminar bars. These bars were pressurelessly sintered to 2050°C without observed cracking but had an average warpage of 20 ± 9°\"--Abstract, p. iv
"]},{"key":"dc:title","label":"Title","values":["Processing to Enable Direct-Write Additive Manufacturing of Ceramics and Ceramic Composites"]}]}],"canonical_facts":{"dc:creator":["Martin, Austin"],"dc:description.abstract":["\"This research focuses on the processing of novel feedstocks for and during direct-write additive manufacturing (AM), specifically the direct ink writing (DIW) and Ceramic On-Demand Extrusion (CODE) manufacturing processes, in order to produce ceramic and ceramic-based composite components. Strongly dispersed, concentrated (φ = 0.42), nanoparticle (d50 ~0.3 µm), zirconia (ZrO2) pastes were used to print densely filled, large continuous volume (≳ 1 cm3) ceramic components. An elastic shear modulus (G’) of 56,000 Pa and yield stresses between 6 and 10 Pa allowed for printed components of 34.5 mm in height over 115 layers without slumping due to partial drying. Printed parts exhibited lateral particle migration during post-processing. Several methods were proposed to improve future feedstocks to prevent this defect. A zirconium diboride (ZrB2) paste (φ = 0.45) was formulated to print fine-featured (<335 >µm), ultra-high temperature ceramic (UHTC) monoliths. The final ZrB2-based paste exhibited an elastic shear modulus of ~104 Pa, flow index of 0.34, and flow stress of ~40 Pa, as-designed for monolithic printing. In discrete multi-material printing, dielectric and conductor formulations were printed together to established considerations for co-DIW of ceramic electronic packaging technologies. Low temperature co-fired ceramic (LTCC) structures were demonstrated by co-printing but were not successfully post-processed due to mismatched co-drying. In graded printing, a Mo (φ = 0.45) paste was developed to print with ZrB2. These formulations were successfully combined to 3D print 11 layer, 10% gradings between the constituents into laminar bars. These bars were pressurelessly sintered to 2050°C without observed cracking but had an average warpage of 20 ± 9°\"--Abstract, p. iv
"],"dc:identifier":["https://scholarsmine.mst.edu/doctoral_dissertations/3215"],"dc:subject":["Additive manufacturing","Direct ink write","Functionally graded materials","Low temperature co-fired ceramics","Robocasting","Ultra-high temperature ceramics","Materials Science and Engineering"],"dc:title":["Processing to Enable Direct-Write Additive Manufacturing of Ceramics and Ceramic Composites"],"dc:type":["Dissertation - Open Access"],"thesis:degree_name":["Ph. D. in Materials Science and Engineering"],"thesis:institution_name":["Missouri University of Science and Technology"]},"updated_at":"2026-07-24T03:18:18Z"}