Literature Library

Gelcasting of alumina

Young AC, Omatete OO, Janney MA, Menchhofer PA (1991) — J. Am. Ceram. Soc. 74(3):612–618

Foundational gelcasting paper — established the technique.

Low-toxicity gelcasting systems

Janney MA, Omatete OO, Walls CA, Nuber SD, Kirby GH (1998) — J. Am. Ceram. Soc. 81(3):581–591

Shift from acrylamide to safer binders.

Gelcasting of zirconia using agarose

Adolfsson E (2006) — J. Am. Ceram. Soc. 89(6):1897–1902

Agar gelcasting — thermoreversible, non-toxic, fast gelation. Gels at ~32°C on cooling. Storage modulus increases ~40% when cooled to 5°C vs 25°C. Sintered densities >99%.

Alumina bodies with near-to-theoretical density by aqueous gelcasting using concentrated agarose solutions

Santacruz I, Nieto MI, Moreno R (2005) — Ceram. Int. 31(3):439–445

Key method paper: preparing concentrated agarose solutions (up to 5.6 wt%) via pressure cooker (>110°C). Enables higher solids loading (55 vol%), lower shrinkage (<5%), green density >60%. Sintered density >99%.

Agar-based aqueous gel casting of barium titanate ceramics

Munro CD, Plucknett KP (2011) — Int. J. Appl. Ceram. Technol. 8(3):597–609

Agar gelcasting of BaTiO₃ with bimodal powder. Comprehensive oscillatory rheometry during gelation. Green densities up to 53.2%. High aspect ratio features (7:1) and CNC green machining demonstrated.

Aqueous gelcasting: a versatile and low-toxic technique

Montanaro L et al. (2019) — Ceram. Int. 45(7):9653–9673

Comprehensive review covering agar, starch, cellulose systems.

Gel casting method: a review

Babashov VG, Varrik NM (2023) — Glass Ceram. 79:433–445

Covers large parts (>30 cm) including refractories.

Fabricating 4m CIOMP-SiC mirror blank

Zhang G, Cui C, Dong B, Cao Q (2019) — SPIE Proceedings

4-meter diameter gelcast SiC — largest demonstrated gelcast piece.

Defect-free drying of large fine-particle zirconia compacts by gelcasting

Trunec M, Stastny P, Kastyl J (2022) — J. Eur. Ceram. Soc.

Drying protocol for large gelcast bodies without cracking.

Tuning mechanical properties of gelcast bodies during drying

Wang C, Chen Z, Liu L, Huang Z (2026) — Processes 14(4):632

Flexible crosslinks increase strain tolerance 58.3%.

Colloidal shaping of alumina by thermally induced gelation of methylcellulose

Hareesh USN et al. (2011) — J. Am. Ceram. Soc. 94(1)

Methylcellulose alternative — gels on heating (inverse of agar).

Processing of porous ceramics by starch consolidation

Lyckfeldt O, Ferreira JMF (1998) — J. Eur. Ceram. Soc. 18(2):131–140

Foundational paper on starch as consolidation agent.

Starch consolidation of red clay-based ceramic slurry inside a pressure-cooking system

Menchavez RL, Adavan CRM, Calgas JM (2014) — Mater. Res. 17(1):157–167

First application of starch consolidation to red clay (terracotta-like) using a pressure cooker. Compressive strengths 82–255 MPa in fired bodies. Procedure uses pressure cooking, not standard oven.

Starch consolidation casting of cordierite precursor mixtures — rheological behavior and green body properties

Sandoval ML, Talou MH, Tomba Martinez AG, Camerucci MA, Gregorová E, Pabst W (2015) — J. Am. Ceram. Soc. 98(10):3014–3021

Corn vs. potato starch comparison in cordierite (kaolin/talc/alumina) slips. Gelatinization onset 61–63°C (potato) vs. 72–73°C (corn). Green body mechanical properties via diametral compression.

Rapid starch consolidation of red clay-based ceramic slurry under simultaneous pressure-cooking and microwave irradiation

Plaza AB, Buenavista AD, Menchavez RL (2014) — Ceram. Int. 40(14):14997–15006

Microwave + pressure cooker reduces starch consolidation time to 2.5 minutes. Uses same red clay system as Menchavez 2014. Demonstrates large-scale prototype fabrication with empirical scaling equations.

Research progress on low-pressure injection molding

Momeni V et al. (2022) — Materials 16(1):379

Comprehensive review. Confirms silicone mold compatibility.

Geopolymer technology: state of the art

Duxson P, Fernandez-Jimenez A, Provis JL et al. (2007) — J. Mater. Sci. 42:2917–2933

Classic geopolymer overview.

Why geopolymers are key to a sustainable world

Kriven WM et al. (2024) — J. Am. Ceram. Soc. 107(8):5159–5177

Current state of geopolymer applications and sustainability case.

Geopolymer casting review

Mokhtari S, Kriven WM (2024) — J. Am. Ceram. Soc. 107(8)

Casting-specific geopolymer methods.

PMMA-based open-cell porous plastics for high-pressure ceramic casting

Ergun Y, Dirier C, Tanoglu M (2004) — Mater. Sci. Eng. A

Characterizes PMMA porous mold properties for HPSC.

Synthesis and characterisation of porous PMMA for use in pressure casting of ceramics

Gibson CM (2013) — PhD thesis

Comprehensive guide to replicating gypsum porosity in PMMA.

Development and characterization of PMMA for HPSC sanitaryware

Ergun Y (2004) — PhD thesis, IYTE

Open access. PMMA mold development for sanitaryware.

Pressure casting improves productivity

Blanchard E (1988) — Am. Ceram. Soc. Bull. 67(10)

Classic paper — pressure vs. cycle time curves.

COMPACTCAST 300 — next generation pressure casting

DORST Technologies (2022) — cfi/Ber. DKG 99(1)

Technical paper on DORST COMPACTCAST 300 system — minimized elastic deformation at high casting pressure.

Flexi mold slip casting: a novel integration of 3D printing with traditional manufacturing

Anil A, Nadimpalli R (2025) — Ceram. Int.

Only published paper on flexible slip casting molds. SLS-TPU with microporosity.

Ultrafast universal fabrication of configurable porous silicone-based elastomers by Joule heating chemistry

Xu F et al. (2024) — PNAS 121(11):e2317440121

~5 µm pores in silicone. Most promising small-pore method.

Permanent superhydrophilic surface modification in microporous PDMS sponge

Bakshi S et al. (2019) — J. Colloid Interface Sci. 552:34–42

PAA UV-grafting on porous PDMS — contact angle ~9°, stable 18+ months.

Digital design and manufacturing of architectural ceramics

Winn KR (2008) — University of Arizona

SLA-printed masters for slip casting molds.

Freeze-casting of porous ceramics: a review of current achievements and issues

Deville S (2008) — Adv. Eng. Mater. 10(3):155–169

Comprehensive review of freeze-casting fundamentals and process parameters.

Ice-templating, freeze casting: beyond materials processing

Deville S (2013) — J. Mater. Res. 28(17):2202–2219

Updated review covering dense and porous ceramics via freeze casting.

Freezing as a path to build complex composites

Deville S, Saiz E, Nalla RK, Tomsia AP (2006) — Science 311(5760):515–518

Landmark freeze casting paper. Directional freezing of ceramic slurries produces nacre-like lamellar structures. Dense composites by infiltration. HAP scaffolds for bone with 4× strength improvement.

Ice-templated porous alumina structures

Deville S, Saiz E, Tomsia AP (2007) — Acta Materialia 55(6):1965–1974

Detailed follow-up on microstructure control: lamellar wavelength vs. ice front velocity, anisotropic ice kinetics. Complete procedure: 20 vol% alumina, Darvan C dispersant, copper cold plate, liquid nitrogen cooling.

Porous ceramic bodies with interconnected porosity prepared by a novel freeze-casting technique

Araki K, Halloran JW (2005) — J. Am. Ceram. Soc. 88(5):1108–1114

Camphene-based freeze casting — sublimes at room temperature, no freeze dryer needed. Pore channels replicate camphene dendrites. Nearly circular pore cross-sections.

Stability of aqueous alpha-alumina suspensions with poly(methacrylic acid) polyelectrolyte

Cesarano J, Aksay IA, Bleier A (1988) — J. Am. Ceram. Soc. 71(4):250–255

Foundation for understanding colloidal stabilization in ceramic slips.

Method for molding ceramic powders using a water-based gel casting

Janney MA (1990) — US Patent 4,894,194

Original gelcasting patent — established gel-based green body strengthening.