Transforming FDM into a high-performance tool for multifunctional ceramic 3YSZ fabrication

This work demonstrates the additive manufacturing of 3Yttria-Stabilised Zirconia (3YSZ) via Fused Deposition Modeling (FDM) and subsequent sintering at 1475 °C. The influence of infill geometry and density on dielectric, mechanical, thermal, and microstructural behaviour was systematically studied. SEM confirmed uniform grain growth and phase distribution. Density and porosity data further validated the influence of design and sintering on final part quality. Thermal expansion analysis indicated structural stability at elevated temperatures. Flexural strength peaked at 187.5 MPa with 75% honeycomb infill, decreasing to 48.75 MPa at 50%, reflecting the role of internal architecture in mechanical performance. A high dielectric constant (ε ≈ 35) was observed for 100% line infill, while gyroid and honeycomb architectures showed significantly reduced values (ε ≈ 2–9.15), revealing strong geometry-dependent dielectric transparency. The absence of cracks in sintered parts highlights the effectiveness of the thermal strategy. These findings establish FDM-processed YSZ as a tunable, high-performance ceramic for advanced structural and electronic applications.