Novel ceramic processing method for substitution of toxic plasticizers

Abstract A systematic screening of plasticisers for a polyvinyl butyral based binder system revealed that dibutyl maleate, dibutyl adipate and Pycal 94 are promising and less toxic alternatives to the very harmful but frequently used dibutyl phthalate. Pycal 94 seems especially promising as it unlike the two other candidates did not require a co-plasticiser, such as a polyethylene glycol, thus simplifying the system and reducing the risk of unwanted cross-interactions. An effective and systematic procedure for substitution of the plasticiser, while maintaining chemical compatibility and mechanical properties, was also demonstrated. Incompatible systems were discarded in an initial broad screening while primary systems were further evaluated based on debinding properties, mechanical properties, flow behavior as well as sintering properties of ceramic tapes. The thermomechanical characterization performed on dried drops of binder and their corresponding tapes show strong similarities in the strain/stress profiles, validating the qualitative method used.