Ceramics are widely used across sectors such as construction, product design, electronics and healthcare. Their durability, heat resistance and versatility make them highly relevant for architects and product designers. Researchers at Empa are now exploring a new way to improve ceramic performance. Instead of focusing only on the material itself, they are studying its microscopic structure—specifically, the grain boundaries.

From Raw Clay To Advanced Materials

Ceramic production follows a well-known process. Fine mineral particles are shaped into a ‘green body’, dried, and then fired at high temperatures. During this step, known as sintering, the particles fuse into a solid material.

Traditional ceramics often focus on aesthetics. In contrast, technical ceramics are engineered for performance. Scientists carefully control composition, grain size and processing conditions. This precision allows them to create materials with specific properties. In design, these ceramics can be used for façade elements, coatings or high-performance components.

The Role Of Grain Boundaries

Until recently, most research focused on the grains themselves. Empa scientists are now examining the interfaces between these grains, known as grain boundaries. These boundaries are extremely small but have a major impact on performance.

Grain boundaries differ from the grains in both structure and chemistry. They can weaken a material or improve its properties. For example, they can influence strength, transparency and conductivity. Understanding these interfaces opens up new possibilities for material innovation.

Engineering Material Performance

The field of grain boundary engineering aims to control these interfaces in a targeted way. The researchers use aluminium oxide as a model material. This ceramic is widely used and well understood. They study how different factors affect grain boundaries. These include doping with rare-earth elements, grain size and pressure during sintering. By adjusting these variables, they aim to fine-tune material properties.

This approach could lead to ceramics that are stronger, lighter or even translucent. Such qualities are valuable for architectural applications, lighting elements and advanced product design.

Towards More Efficient And Durable Materials

This research reflects a broader shift in materials science. Scientists now design materials at the microscopic level to improve performance at a larger scale. Better-performing ceramics can last longer and require fewer resources.

These developments support circular design strategies. They also expand the potential of ceramics in design disciplines. In the future, grain boundary engineering may enable more sustainable and high-performance material solutions.

Source & image: Empa