Memoria Investigaciones en Ingeniería, núm. 30 (2026). pp. 14-29
https://doi.org/10.36561/ING.30.3
ISSN 2301-1092 ISSN (en línea) 2301-1106 Universidad de Montevideo, Uruguay
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Additive Manufacturing of Cupric Oxide via Direct Ink Writing
Fabricación aditiva de óxido cúprico mediante escritura directa con tinta
Fabricação aditiva de óxido cúprico por escrita direta de tinta
Muhammad Ali
1
, Shaheryar A. Khan
2
(*), Aqueel Shah
3
, Antash Najib
4
, Abbas Hussain
5
Recibido: 18/08/2025 Aceptado: 24/11/2025
Summary. - The DIW approach offers numerous benefits, including expedited prototyping, cost-effectiveness, reduced
waste in manufacturing, and enhanced design flexibility. It's currently a popular production method for building
materials and has great potential for porous and electronic materials. In this study, porous cupric oxide (CuO) ceramics
were fabricated using a direct ink writing (DIW) approach based on a copper particleladen aqueous precursor. The
ink formulation was optimized to achieve stable extrusion and crack-free green bodies, yielding a final composition of
68.0 wt% Cu, 31.3 wt% water, and 0.6 wt% CMC. Following oxidation and sintering in air, the printed structures
exhibited a bulk density of 3.60 ± 0.20 g cm⁻³ and a corresponding theoretical porosity of 43.7 ± 0.9%. X-ray diffraction
confirmed nearly phase-pure monoclinic CuO with no detectable Cu or Cu₂O residues. The printed components
exhibited an interconnected, porous microstructure and a four-point-probe resistivity of 10.5 ± 0.3 Ω·m at 25 °C,
reflecting the influence of high porosity on charge transport. The DIW route demonstrated here provides a controllable
pathway for producing porous CuO architectures with tunable microstructure and moderate electrical conductivity.
These characteristics suggest potential applicability in gas filtration, catalytic supports, and electrochemical sensing;
however, device-level validation is still required to fully assess functional performance.
Keywords: Advanced Ceramics, Direct Ink Writing, Additive Manufacturing, Copper Oxide, Cupric Oxide, Binder,
Ceramics, Green Body, Brown Body, Sintered Ceramic, Resistivity Analysis of Ceramic, Aqueous Binder Slurry,
Particle Laden Slurry
(*) Corresponding author.
1
Postgraduate Student, National University of Sciences and Technology (Pakistan), ime.322.ali@gmail.com,
ORCID iD: https://orcid.org/0009-0006-8014-5737
2
Associate Professor and Head of the Department of Mechanical Engineering., DHA Suffa University (Pakistan), shaheryar.atta@dsu.edu.pk,
ORCID iD: https://orcid.org/0000-0003-1600-7322
3
Professor, National University of Sciences and Technology (Pakistan), a.shah@smme.nust.edu.pk,
ORCID iD: https://orcid.org/0000-0003-2814-3073
4
Assistant Professor, National University of Sciences and Technology (Pakistan), antash.najib@pnec.nust.edu.pk,
ORCID iD: https://orcid.org/0000-0002-4845-9350
5
Assistant Professor, National University of Sciences and Technology (Pakistan), abbas.hussain@pnec.nust.edu.pk,
ORCID iD: https://orcid.org/0009-0008-1680-6507
M. Ali, S. A. Khan, A. Shah, A. Najib, A. Hussain
Memoria Investigaciones en Ingeniería, núm. 30 (2026). pp. 14-29
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ISSN 2301-1092 ISSN (en línea) 2301-1106 Universidad de Montevideo, Uruguay 15
Resumen. - El método DIW ofrece numerosas ventajas, como la creación rápida de prototipos, la rentabilidad, la
reducción de residuos en la fabricación y una mayor flexibilidad de diseño. Actualmente es un método de producción
popular para materiales de construcción y tiene un gran potencial para materiales porosos y electrónicos. En este
estudio, se fabricaron cerámicas porosas de óxido cúprico (CuO) utilizando un método de escritura directa con tinta
(DIW) basado en un precursor acuoso cargado con partículas de cobre. La formulación de la tinta se optimizó para
lograr una extrusión estable y cuerpos verdes sin grietas, obteniendo una composición final de 68,0 % en peso de Cu,
31,3 % en peso de agua y 0,6 % en peso de CMC. Tras la oxidación y sinterización al aire, las estructuras impresas
mostraron una densidad aparente de 3,60 ± 0,20 g cm⁻³ y una porosidad teórica correspondiente de 43,7 ± 0,9 %. La
difracción de rayos X confirmó CuO monoclínico casi puro en fase, sin residuos detectables de Cu o Cu₂O. Los
componentes impresos exhibieron una microestructura porosa interconectada y una resistividad de cuatro puntas de
10,5 ± 0,3 Ω·m a 25 °C, lo que refleja la influencia de la alta porosidad en el transporte de carga. La ruta de impresión
directa con tinta (DIW) demostrada aquí proporciona una vía controlable para producir arquitecturas porosas de
CuO con microestructura ajustable y conductividad eléctrica moderada. Estas características sugieren una posible
aplicabilidad en filtración de gases, soportes catalíticos y detección electroquímica; sin embargo, aún se requiere una
validación a nivel de dispositivo para evaluar completamente su rendimiento funcional.
Palabras clave: Cerámica avanzada, Impresión directa con tinta, Fabricación aditiva, Óxido de cobre, Óxido cúprico,
Aglutinante, Cerámica, Cuerpo verde, Cuerpo marrón, Cerámica sinterizada, Análisis de resistividad de cerámica,
Suspensión acuosa de aglutinante, Suspensión con partículas
Resumo. - A abordagem de escrita direta de tinta (DIW) oferece inúmeros benefícios, incluindo prototipagem
acelerada, custo-benefício, redução de desperdício na fabricação e maior flexibilidade de design. Atualmente, é um
método de produção popular para materiais de construção e tem grande potencial para materiais porosos e
eletrônicos. Neste estudo, cerâmicas porosas de óxido cúprico (CuO) foram fabricadas utilizando uma abordagem de
escrita direta de tinta (DIW) baseada em um precursor aquoso carregado com partículas de cobre. A formulação da
tinta foi otimizada para obter extrusão estável e corpos verdes sem trincas, resultando em uma composição final de
68,0% em peso de Cu, 31,3% em peso de água e 0,6% em peso de CMC. Após oxidação e sinterização ao ar, as
estruturas impressas apresentaram uma densidade aparente de 3,60 ± 0,20 g cm⁻³ e uma porosidade teórica
correspondente de 43,7 ± 0,9%. A difração de raios X confirmou a presença de CuO monoclínico quase puro, sem
resíduos detectáveis de Cu ou Cu₂O. Os componentes impressos exibiram uma microestrutura porosa interconectada
e uma resistividade de quatro pontos de 10,5 ± 0,3 Ω·m a 25 °C, refletindo a influência da alta porosidade no transporte
de carga. A rota DIW demonstrada aqui fornece um caminho controlável para produzir arquiteturas porosas de CuO
com microestrutura ajustável e condutividade elétrica moderada. Essas características sugerem potencial
aplicabilidade em filtração de gases, suportes catalíticos e sensores eletroquímicos; no entanto, a validação em nível
de dispositivo ainda é necessária para avaliar completamente o desempenho funcional.
Palavras-chave: Cerâmicas Avançadas, Impressão Direta de Tinta, Manufatura Aditiva, Óxido de Cobre, Óxido
Cúprico, Aglutinante, Cerâmicas, Corpo Verde, Corpo Marrom, Cerâmica Sinterizada, Análise de Resistividade de
Cerâmica, Suspensão Aquosa de Aglutinante, Suspensão com Partículas
M. Ali, S. A. Khan, A. Shah, A. Najib, A. Hussain
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ISSN 2301-1092 ISSN (en línea) 2301-1106 Universidad de Montevideo, Uruguay 16
Graphical abstract.
1. Introduction. - The demand for materials with enhanced performance has created an everlasting need for the
emergence of advanced materials. In today’s world, advanced ceramics have primarily supplanted traditional materials.
This technological change is motivated and boosted by the Asian markets in Japan and China [1].
Ceramics are well-known materials among other inorganic materials for their peculiar characteristics due to their
chemical and physical properties [2]. High hardness, high strength, low thermal conductivity, and biocompatibility are
some of the unique characteristics of advanced ceramics [36]. These materials have an enhanced resistance to wear
governed by their microstructures that enable their application in various areas such as aerospace, biomedical, solar
cells, fuel cells, heat exchangers, turbines, and piezo-electric devices [7].
Cupric oxide (CuO) is a black-colored ceramic material known as cupric oxide or copper (ii) oxide [8]. It is a transition
metal oxide with a high surface-to-volume ratio, porosity, and monoclinic crystal structure [9,10]. It holds unique
importance due to its comparable efficiency as a catalytic agent, superconducting property, anti-microbial agent, and
energy-storing characteristics [9,11,12]. It is used in various domains today, including electronics, biomedical devices,
energy harvesting systems, chemical catalysts for different chemical reactions, solid self-lubricants, and anti-microbial
textiles [1315]. It is used as a p-type semiconductor and magnetic storage media, finding its application in capacitors,
electrodes, and different gas-sensing probes [1619]. It is used to sense gases in the atmosphere and different
biomedical sensing devices, including but not limited to CO2, NO2, H2, H2S, CO, benzyne, alcohol, ethanol, and
methanol [10,2024]. Studies show that CuO has the potential to replace the graphite anodes in lithium-ion batteries,
as it is less expensive, safer, and more environmentally favorable than graphite [25]. CuO-based biomedical instruments
detect blood protein patterns and blood glucose levels [16]. CuO also serves the environment by removing pollutants
from the aqueous environment, including fluorides, arsenic, benzene, and toluene [2628]. Its adsorption property
removes lead, acrylic acid, and ciprofloxacin from different media, making CuO a good choice as a water-treating agent
[26].
Conventional techniques for producing monolithic ceramic parts have many disadvantages, such as reliance on molds,
lengthy production cycles, low material utilization rate, high material waste, high production cost, limited production
volume, poor repeatability, and lack of microstructure control. [29]. These techniques include dry pressing, casting,
micromachining, and injection molding [30,31]. Dry pressing and casting have similar limitations, such as the
requirement for molds and the inability to produce complex shapes readily [32]. Fractures, porosity, and warpage are a
few of the defects that can occur during the dry pressing and casting of ceramics. Nevertheless, these processes are
protracted processes that frequently result in a product with an unstable microstructure [30].
M. Ali, S. A. Khan, A. Shah, A. Najib, A. Hussain
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Micromachining in ceramics is limited to low-volume production due to the high cost of the required machining tools,
the geometric constraints that impede the production of intricate patterns, and the material's fragility [30].
Additive manufacturing (AM) has disrupted the manufacturing space and is being utilized to circumvent the limitations
of conventional manufacturing techniques [3335]. The technique builds monolithic parts layer-by-layer using 3D
CAD data, resulting in the fabrication of complex geometries and reducing machining costs [3638]. The technique
provides freedom of design, increased finish quality, and reduced design-to-production lead time [39].
AM techniques have been developed for different materials [40,41], however, the Direct Ink Writing (DIW) technique
is the most flexible, which can additively manufacture polymers, metals, ceramics, composites, and biological materials
[42–44]. The DIW technique employs viscous pastes termed “inks” to produce monolithic parts [45]. The inks can be
loaded with particles of ceramics to produce ceramic green bodies that can be later sintered in a furnace to produce a
monolithic ceramic part [46]. Furthermore, pre-ceramic metal powder may also be utilized, which will oxidize in the
furnace to produce ceramic parts[47].
The composition of the ink can be customized based on the specific application and desired properties of the printed
part [43]. The combination of solid particles, solvents, binders, surfactants, plasticizers, rheology modifiers, and
crosslinkers allows for a wide range of ink formulations that can be optimized for different printing methods, materials,
and part geometries [45,4851].
Despite extensive research on DIW of ceramic materials, the additive manufacturing of cupric oxide remains largely
unexplored, particularly when derived from metallic copper precursors. Existing DIW studies on ceramics primarily
utilize oxide powders, solgel routes, or UV-curable suspensions, whereas the transformation of a water-based metallic
copper ink into a monolithic CuO ceramic through controlled oxidation and sintering has not been previously reported.
In this study, we establish a reproducible process window for printing crack-free CuO structures using an aqueous
CMC-based binder formulation with optimized copper loading. The work further demonstrates that the resulting 3D-
printed CuO exhibits a combination of high porosity and measurable electrical conductivity, enabling its potential use
in sensing and filtration applications. This contribution distinguishes the present study from prior DIW efforts and
provides a scalable, low-cost pathway for fabricating functional CuO architectures.
This paper presents the additive manufacturing of copper oxide via the Direct Ink Writing (DIW) technique. A pre-
ceramic green body was produced using an aqueous ink loaded with copper particles. The green body was sintered to
form a monolithic ceramic part and characterized for its density, structure, and electrical conductivity. The results
demonstrate that DIW is a viable technique for the manufacturing of monolithic parts from CuO. Unlike most existing
DIW ceramics that utilize oxide powders, sol-gel routes, or UV-curable suspensions, this work establishes the first
reported transformation of a water-based metallic copper ink into a monolithic CuO ceramic through a controlled
oxidation and sintering process.
2. Materials and methods. - Copper powder, DI water (De-Ionized Water), and CMC (Carboxymethyl Cellulose)
binder were the three components used for this research. Copper powder with a particle size of 10µm was purchased
and imported from Vanuatu. The DI water was used in this experiment to ensure that no impurity was added to the
materials during the manufacturing process, affecting the chemical composition of the slurry. CMC binder, holding
CAS number 9000-11-7, was purchased from Purge Chemical Industries, Karachi, Pakistan.
2.1 Preparation of copper-loaded pre-ceramic ink. - The pre-ceramic ink was formulated as a copper particleladen
aqueous binder system. The aqueous binder was first prepared by dissolving 0.20 g of CMC in 10.0 g of deionized
water, followed by manual stirring for 3 minutes to ensure complete homogenization. Subsequently, 21.7 g of copper
powder was incorporated into the binder solution. The copper powder was added intermittently and stirred continuously
to promote uniform wetting and dispersion. Manual stirring throughout this process ensured homogeneous distribution
of the metallic particles within the aqueous matrix. The final ink composition on a massmass basis consisted of 68.0
wt% copper, 31.3 wt% water, and 0.6 wt% CMC.
M. Ali, S. A. Khan, A. Shah, A. Najib, A. Hussain
Memoria Investigaciones en Ingeniería, núm. 30 (2026). pp. 14-29
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Multiple solid loadings were evaluated to identify the optimal formulation for DIW. Copper contents lower than 68
wt% resulted in insufficient structural integrity during drying, leading to cracking of the green bodies. Conversely,
higher copper loadings produced excessively dense pastes that consistently clogged the nozzle during extrusion. The
polymeric binder concentration also governed drying behaviour: CMC levels above 0.6 wt% increased shrinkage and
deformation during solvent removal, whereas lower binder contents led to cracking due to inadequate particleparticle
bridging. Based on these observations, the composition of 68.0 wt% Cu and 0.6 wt% CMC in a 31.3 wt% aqueous
phase was identified as the optimal mass fraction combination for achieving stable extrusion, shape retention, and
crack-free green bodies.
Although the ink was formulated and optimized on a massmass basis, its rheological behavior was also considered
during process development, as DIW printability is strongly governed by viscosity, shear-thinning characteristics, and
yield stress. While full rheological profiling (e.g., viscometry or oscillatory shear measurements) was not performed in
this study, the formulation exhibited all qualitative indicators of DIW-compatible flow behavior. Specifically, the ink
demonstrated continuous filament formation under extrusion, maintained structural integrity after deposition, and
showed no signs of uncontrolled spreading, all of which are consistent with shear-thinning pastes reported in DIW
literature. The absence of nozzle clogging or die swell further suggests that the yield stress lies within a suitable range
for stable extrusion. The optimized solid and binder mass fractions (68.0 wt% Cu and 0.6 wt% CMC) were therefore
selected not only for their influence on drying and green-body integrity, but also for their empirically validated
rheological performance during printing.
2.2 Direct Ing Writing. - Parts were manufactured using a modified Creality Ender-3 platform that was adapted for
direct ink writing (DIW) through mechanical and control-system modifications. The stock thermoplastic extruder
assembly was removed and replaced with a custom-designed DIW print head. The print head consisted of a 50 mL
pneumatic dispensing cartridge fitted with a tapered nozzle of 0.4 mm exit diameter, which deposited the copper-loaded
pre-ceramic slurry onto a glass build platform. Extrusion was actuated by a regulated pneumatic pressure system
(01 MPa), supplied by a laboratory compressor and controlled by an electronic solenoid valve interfaced with the
printer’s control board. Fine adjustment of the extrusion pressure was achieved using an inline pressure regulator to
ensure stable and continuous filament formation.
The Ender-3 is originally designed for stepper-driven thermoplastic extrusion and, therefore, its firmware was modified
so that the E-axis extrusion commands in the G-code toggled the solenoid valve rather than driving a stepper motor.
Geometric parameters, including layer height, nozzle speed, infill pattern, and wall thickness, were defined in the slicing
software (Ultimaker Cura), while the extrusion rate was governed exclusively by pneumatic pressure. These
modifications enabled reliable deposition of the high-viscosity CuO precursor paste while preserving the positional
accuracy inherent to the FFF motion system.
All samples were manufactured under controlled laboratory conditions of 25 ± 1 °C and 50% relative humidity. Fig. 1
illustrates the modified DIW setup along with the part geometry selected for DIW-based CuO ceramic fabrication, and
the corresponding DIW process parameters are summarized in Table 1. The printed aerofoil specimen (NACA 2412)
had an overall chord length of 100 mm, a maximum thickness of 15.54 mm, and a span of 3 mm (z-axis). The outer
shell thickness was set to 0.8 mm, with a rectilinear infill density of 100%. These dimensions were chosen to minimize
drying-induced warpage and to promote uniform shrinkage during sintering.
M. Ali, S. A. Khan, A. Shah, A. Najib, A. Hussain
Memoria Investigaciones en Ingeniería, núm. 30 (2026). pp. 14-29
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Figure I. The Direct Ink Writing (DIW) setup.
Parameter
Value
Nozzle Diameter
0.4 mm
Layer Height
0.2 mm
Extrusion Width
0.4 mm
Linear Speed
20 mm.s-1
Raster Angle
45 degrees
Infill Pattern
Rectilinear
Infill Density
100%
Wall thickness
0.8 mm
Air Pressure
0.2 MPa
Table I. Parameters of the Direct Ink Writing Process.
2.3 Drying, demolding, and sintering. - The printed green bodies were dried at room temperature for 24 h and
subsequently sintered in a programmable air furnace concurrently. The temperature schedule consisted of an initial
heating step from room temperature to 400 °C at a rate of 5 °C/min, followed by a dwell of 45 min to ensure complete
binder burnout. The temperature was then increased from 400 to 900 °C at 5 °C/min, where the samples were held for
180 min to promote oxidation and densification. After sintering, the furnace was allowed to cool naturally to room
temperature at an uncontrolled rate. All specimens were sintered in ambient air without additional oxygen flow. The
multi-step sintering regime is illustrated in Figure II.
Figure II. The Direct Ink Writing (DIW) setup.
3. Results and discussion. -
3.1 Sintered ceramic body. - The transformation of the DIW sample to the final sintered ceramic body is illustrated
in Figure III. The technique can produce monolithic parts using pre-ceramic slurry without cracking and warping. An
M. Ali, S. A. Khan, A. Shah, A. Najib, A. Hussain
Memoria Investigaciones en Ingeniería, núm. 30 (2026). pp. 14-29
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ISSN 2301-1092 ISSN (en línea) 2301-1106 Universidad de Montevideo, Uruguay 20
isotropic shrinkage of 4.1 ± 0.2 % (n=5) was observed from the CAD model to the sintered body. It can be concluded
that the DIW technique is a viable option for the manufacturing of monolithic ceramic parts. Simple and complex part
geometries can be designed in a CAD environment and implemented readily for function-specific applications.
Figure III. Transformation from the DIW part to the sintered monolithic ceramic body (Aerofoil Geometry).
3.2 XRD Analysis. - The X-ray diffractogram of the sintered CuO sample is illustrated in Figure IV. The XRD analysis
demonstrates that the Cu particles have uniformly oxidized into CuO as the experimental pattern shows an excellent
match with the monoclinic CuO reference pattern (Crystallography Open Database) [52]. A quantitative analysis by
Rietveld refinement using FullProf software was performed to identify the phase ratio. The results of the refinement
indicated that the sample is 99.8 % phase-pure CuO. No significant secondary phases, such as residual Cu or Cu2O,
were detected above the instrument's detection limit.
The degree of crystallinity was determined by integrating the area under the crystalline peaks and the background
amorphous hump. Using the peak analyser tool in OriginLab software, the crystallinity degree of the sample was
calculated to be 65.78%.
The crystallite size of the XRD patterns was estimated using Scherrer's equation:

 󰇛󰇜
where D is the crystallite size, k is the so-called shape factor (0.9), λ is the wavelength (0.15418 nm, CuKα), β is the
Full Width at Half Maximum (FWHM), and θ is the diffraction angle [53]. To ensure an accurate representation, the
crystallite size was calculated using the FWHM of the three most intense peaks: (111), (111), and (200) located at
approximately 35.5°, 38.7°, and 39.8° 2Theta, respectively). The FWHM values were corrected for instrumental
broadening using a standard LaB6 reference sample. Exploiting the average of the data derived from these three peaks,
an average crystallite size of 71.75 nm was determined, with an estimated standard deviation (error) of 2.1 nm is
reported for the measurement. The sample was identified as having a Monoclinic Crystal System with refined lattice
parameters.
Figure IV. X-ray diffractogram of sintered CuO sample.
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The refined lattice parameters of the sintered phase were found to be a = 4.68370 Å, b = 3.42260 Å, c = 5.12880 Å,
and β = 99.54°. These values are in excellent agreement with the reported unit-cell dimensions for monoclinic CuO
(tenorite), which are typically quoted as a ≈ 4.68 Å, b ≈ 3.42 Å, c ≈ 5.13 Å, and β ≈ 99.5° in standard crystallographic
databases and the literature. The close match between the extracted parameters and the reference values indicates that
the as-sintered material is phase-pure CuO with negligible lattice distortion. Any minor differences are within expected
experimental uncertainty and may arise from instrument calibration, residual micro-strain introduced during the
oxidation/sintering cycle, or slight non-stoichiometry. Peak broadening observed in the diffractogram (Scherrer
crystallite size 72 nm) is consistent with the finite crystallite size and could also contribute to small uncertainties in
the refined cell metrics.
3.3 Morphology. - The morphology of copper powder and the sintered CuO ceramic was studied under a Scanning
Electron Microscope. SEM micrographs of copper powder in Fig. 5 (a and b) depict the powder having an average
particle size of 10μm. The SEM micrographs demonstrate the agglomeration of the copper powder. The copper powder
was not subjected to ball milling to prevent it from early oxidation.
Figure V (c and d) shows the SEM images of the CuO sintered sample manufactured using additive manufacturing.
The micrographs show that powder particles have sintered into a porous structure. This porosity allows for the
application of additively manufactured CuO parts in applications such as gas sensing and pollutant filtration [54].
Figure V. (a) SEM image of copper powder at x100 magnification. (b) SEM image of copper powder at x200
magnification. (c) SEM image of sintered CuO ceramic at x200 magnification. (d) SEM image of sintered CuO
ceramic at x500 magnification.
3.4 Porosity and Density. - The surface porosity of the sintered sample was estimated through pixel intensity analysis
using the ImageJ software. Pixel intensity analysis is illustrated in Figure VI, where the porous regions are mapped
with red color. The software estimates a mean surface porosity of 40.4%.
(a)
(b)
(c)
(d)