The feasibility of using the Fused Deposition ofCeramics (FDC) process to rapidly fabricate
functional quality advanced ceramic components has been demonstratedl
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5
. This direct
manufacturing technique, by eliminating the need for costly tooling, dramatically reduces
functional prototype development time. This makes it suitable for small quantity production runs
and complex parts. The move from 'feasibility" to a robust, reliable commercial fabrication
tool requires that every aspect ofthe manufacturing be understood and brought under control.
An overview ofthe five basic process steps in FDC: batch compounding, filament fabrication,
fused deposition, binder burnout and sintering will be presented in light ofthis drive toward a
robust process. Tools such as Statistical Process Control and Experimental Design techniques
are being used to monitor, improve, and stabilize each step and sub-process. Hardware and
software modifications have been made to the FD machine to effect the required changes. This
paper will identify the remaining technical barriers to commercialization and our progress in
addressing these issues.Mechanical Engineerin
