Nano-sized polymer-assisted cold sintering and recycling of ceramic composites

Cold sintering is an emerging technology that significantly reduces sintering temperatures by approximately an order of magnitude, down to about 100–200°C. This reduction of processing temperature enables the co-sintering and integration of dissimilar materials, such as ceramics and polymers, into unprecedented composites, where the low-energy consumption densification provides an opportunity for recycling. Here, we cold sintered barium titanate (BaTiO₃)-polytetrafluoroethylene (PTFE) ceramic-polymer composites, demonstrating that nano-sized PTFE polymer powders facilitate co-sintering and enable the recycling of ceramic composites. This approach offers an opportunity for reusing and re-processing ceramic components, thereby promoting sustainability through waste reduction and energy savings.