A novel, environmentally friendly solid freeform fabrication method called Freeze-form Extrusion Fabrication (FEF) has been developed for the fabrication of ceramic-based components. The method is based on deposition of ceramic pastes using water as the media. The ceramic solids loading can be 50 vol. % or higher and initial studies have focused on the use of aluminum oxide (Al2O3). The FEF system components and their interaction are examined, and the main process parameters affecting part geometry defined. 3-D shaped components have been fabricated by extrusion deposition of the ceramic paste in a layer-by-layer fashion. The feasibility of this process has been demonstrated by building components having a simple geometry, such as cylinders and solid or hollow cones. Hollow cones have also been fabricated to demonstrate the ability to build structures with sloped walls.

Meeting Name

16th Annual Solid Freeform Fabrication Symposium (2005: Aug. 1-3, Austin, TX)


Materials Science and Engineering

Second Department

Mechanical and Aerospace Engineering


This work was supported by the Air Force Research Laboratory under Contract FA8650- 04-C-5704

Keywords and Phrases

Adhesive pastes; Ceramic materials; Cones; Deposition; Extrusion; Fabrication; Aluminum oxides; Ceramic pastes; Freeform fabrication method; Layer-by-layers; Part geometry; Simple geometries; Solids loading; System components

Document Type

Article - Conference proceedings

Document Version

Final Version

File Type




Publication Date

03 Aug 2005