Net-shape ceramic processing as a route to ultrafine scale 1-3 connectivity piezoelectric ceramic-polymer composite transducers

In this paper, we report on a new "net-shape" processing method for the fabrication of ultrafine scale 1-3 ceramic structures. We have used Viscous Polymer Processing (VPP), combined with a modified "lost mould" method to obtain lead zirconium titanate (PZT) bristle-blocks with feature sizes of 12 mu m - 100 mu m and aspect ratios of the order of 3-10. Experimental, 1-3 piezo-composite transducer elements have been assembled and we report on their electrical impedance and pulse-echo behavior and demonstrate a close correlation with computer modeling. We conclude that the processing route we have developed has the potential to extend upwards the frequency range of piezo-composite material beyond existing limits.