Optimization of 3D printed grid-like ceramic composite structures for structural and performance evaluation in piezoelectric applications

To maximize the performance of 3D printed piezoelectric grid-like lattice structures, BaTiO 3 /polydimethylsiloxane (BTO/PDMS) frameworks were fabricated via direct ink writing. The ink printability and structural and piezoelectric performance of the printed piezoelectric sensors were evaluated based on the ceramic solid loading, infill ratio, infill angle, layer count, and nozzle diameter. Their influences on the compressive stiffness, flexibility, and piezoelectric coefficient were mapped. The results suggest that the mechanical response is governed primarily by the lattice design and filler content. The piezoelectric coefficient increases with higher ceramic loading, thicker stacks, and denser infill yet remains nearly unchanged with variations in raster angle or nozzle diameter. A lattice structure with 40 wt% ceramic, 40 % infill density and a 90° infill angle offered the best balance of piezoelectric activity, flexibility and mechanical strength. The thickness of the printed object can be adjusted to suit application requirements. Optimum noncontact corona poling was achieved with an electric field of 9.5 kV cm -1 at 80°C for 10 h, with the needle tip positioned 11 mm above the sample; this protocol maximizes the remnant polarization, yielding the highest piezoelectric coefficient (14.9 pC N -1 ) and output voltage (524 mV at 10 N) at 70 wt% solid loading. This decoupled response enables independent optimization of strength, flexibility, and piezoelectric performance without compromising structural integrity or long-term durability.