Spark Plasma Sintering (SPS) has been shown to facilitate rapid densification at low temperatures, making it a promising technology for use in many industries. This study investigates the ability of SPS to aid tailoring of both structural and functional properties in powder-based metal and ceramic components. SPS is used to correlate the manipulation of sintering temperature, pressure, holding time and initial particle size to the porosity and mechanical properties of Ti35Nb7Zr5Ta (TNZT). TNZT is a high titanium entropy alloy that shows promise as a future material for orthopedic implants and understanding the affect of porosity on its mechanical properties is critical for implant design. The “densification maps” provided in this report will allow future researchers and manufacturers to quickly develop samples with specific porosities and understand how each sintering parameter affects densification. SPS is also used to improve the structural and functional properties of All-Solid-State Lithium-ion Batteries (ASSLIBs). Functionally graded composite electrodes are implemented into a novel ASSLIB design. Galvanostatic discharge tests show the new design to improve the energy and power densities of the ASSLIB and scanning electron microscopy (SEM) shows that the new design eliminates delamination at the electrode-electrolyte interface.
