Piezoelectric ceramics with hierarchical macro- and micro-pore channels for sensing applications

Piezoelectric sensors have attracted increasing attention due to their high sensitivity to forces, pressures and acceleration. The use of porous piezoelectric ceramics with aligned pores formed by freeze casting for sensing application also exhibit advantages due to their combination of a high piezoelectric charge coefficient and low permittivity, which leads to an enhancement in sensor sensitivity compared to dense materials. To fabricate porous materials, the process of direct ink writing (DIW) exhibits superiority in terms of structural design as a result of its ability to provide layer-by-layer and mold-free rapid prototyping. This work provides the first demonstration of the fabrication of lead zirconate titanate (PZT) piezoelectric ceramic scaffolds with sophisticated hierarchical porous structures by simultaneous DIW and freeze casting. The morphology of the porous cells and individual layers of the hierarchical porous PZT ceramic scaffolds were designed by adjusting the rheological properties and optimizing the printing path. The effect of cell structure and number of layers on sensing performance was investigated in detail. Manufactured scaffolds with a sandwich structure exhibited a high output voltage (191 V) under the application of 1 N external force, with a sensitivity of 8.98 V·kPa⁻¹. This work provides a new approach to structural design of piezoelectric sensors to inform future efforts in the fabrication of high-performance piezoelectric ceramics with hierarchical porosity with complex and bespoke geometries.