Tape Casting: A Key Technology Driving the Development of Aluminum Nitride Ceramic Substrates

Among the various forming processes for aluminum nitride (AlN) ceramics, traditional methods such as die pressing, hot pressing, and isostatic pressing are well-established but face several challenges. Due to the strong hydrophilicity of AlN powder, contact with water should be minimized during the forming process to avoid oxidation that could compromise material performance. Although hot pressing and isostatic pressing can produce high-performance bulk materials, their high cost and low efficiency make it difficult to meet the ever-growing demand for AlN ceramic substrates in the electronics industry. Against this backdrop, tape casting technology has gradually emerged as a mainstream process for manufacturing aluminum nitride ceramics in electronics.

How Does Tape Casting Prepare Multilayer Aluminum Nitride Ceramics?

The core of this technology lies in mixing aluminum nitride powder with sintering aids, binders, and solvents to form a homogeneous slurry, which is then cast into thin green sheets using a tape caster. Subsequently, these sheets undergo processes such as punching, drilling, metal pattern printing, stacking, and lamination to form multilayer ceramic green bodies. Finally, after high-temperature binder burnout and sintering in a nitrogen atmosphere, dense and high-performance multilayer aluminum nitride ceramics are produced. This process is not only efficient but also particularly suitable for the large-scale production of ceramic substrates.

Process Details Determine Final Performance

The properties of AlN ceramic substrates prepared by tape casting are closely related to multiple process parameters: powder quality, casting parameters, binder burnout, and sintering regimes all require meticulous control. For example, coarser powders are easier to form but struggle to achieve high-quality substrates, while finer powders, though more challenging to process under strictly controlled conditions, often yield superior product quality. The binder burnout process must be gentle and stable, as excessively high temperatures or rapid heating rates can easily cause cracking in the green body. The sintering regime is even more critical, directly determining the final properties of the ceramic, such as thermal conductivity and strength.

Currently, tape casting systems are mainly divided into organic-based and water-based systems. Organic systems face environmental pressure due to the use of toxic solvents, while water-based systems, though environmentally friendly, still require further refinement in drying technology, representing an important direction for future development. For instance, research using a mixed solvent of ethanol and isopropanol has successfully prepared AlN ceramics with a thermal conductivity of 178 W/(m·K), demonstrating the potential of non-aqueous solvent systems.

Conclusion

Tape casting technology, with its advantages of high efficiency, consistent quality, and suitability for mass production, has become an indispensable part of aluminum nitride ceramic substrate manufacturing. As environmental requirements become more stringent and product forms diversify, this technology continues to evolve. Together with other forming processes, it drives the broader application of aluminum nitride ceramics in fields such as electronic packaging and heat dissipation components.

About Xiamen Juci Technology Co., Ltd.

Xiamen Juci Technology Co., Ltd., a national high-tech enterprise dedicated to the R&D and production of high-performance aluminum nitride (AlN) ceramic powders, stands at the forefront of electronic ceramic materials technology. We recognize the growing demand for advanced thermal management substrates and packaging solutions driven by 5G communications, advanced packaging, power modules, and high-brightness LEDs. Beyond supplying premium AlN powders, Juci Technology delivers integrated material solutions incorporating advanced tape casting processes. We collaborate with partners to overcome thermal challenges and lead industry progress together.

Contact:
Xiamen Juci Technology Co., Ltd.

Phone: +86 592 7080230
Email: miki_huang@chinajuci.com
Website: www.jucialnglobal.com