Injection moldings of three types of ultra-fine zirconia powder were investigated. It was demonstrated that powder characteristics involving particle size, particle size distribution, particle shape and specific surface area significantly affect the optimal compositions of binders and ceramic powders, and the properties of sintered compacts. Investigation of the injection molding variables showed that an excessive barrel-deposited value may easily lead to defects in the debound and sintered bodies. It was also demonstrated that the microstructure of a sintered body can be affected by heating rates influencing grain growth, and that suitable heating rates to the high temperature sintering stage for the three powders are different.

Keywords: injection molding; zirconia powder; ceramic sintering