Freeze tape casting is an environmentally friendly manufacturing process related to conventional tape casting. It can be applied to a wide range of substrate materials including ceramics, metals, and polymers.
The key advantage of freeze tape casting is that the porosity in the sheet can be highly engineered. The resulting anisotropic properties along and through the sheet are therefore controllable results of the fabrication process. These properties can be unique to a single direction within the sheet or exhibit variance between through-thickness and in-plane properties. In addition to unique mechanical properties, these materials are notable for their integrity at high temperatures even with large mismatches of coefficients of thermal expansion.
The manufacturing process begins by using a freeze tape caster to create the basic material. Subsequent steps remove water and yield a green tape, which is then sintered to yield the initial product.
The process does not necessarily stop with the creation of the porous tape. The resulting structure can be subsequently infiltrated with a second species to yield a finished material with unique properties. Our applications page details several examples.
Glacigen engineers are available to assist with the development of formulations to enable the casting of all types of materials, as well as any potential subsequent infiltration step.