Hallmarks of BCZT-based piezoceramics: From chemical fundamental to processing route and biomedical applications

Environmentally friendly (Ba,Ca)(Zr,Ti)O₃ ceramics (BCZT) are being investigated as a viable alternative to the leading commercially used lead titanate–zirconate ceramics. These ferro-piezoelectric ceramics exhibit fascinating properties for a range of applications, dependent on several multiscale characteristics, including composition, crystal structure, domain structure, ceramic microstructure and bulk issues. To provide reproducible quality, a thorough grasp of processing control is essential. This review begins with a historical overview of BCZT ceramic development, followed by a phase diagram examination. The morphotropic phase boundary is explored, detailing the intrinsic and extrinsic contributions to the system's piezoelectricity, as well as the critical aspects to consider while processing. The factors to contemplate for an industrially scalable solid state processing pathway are reviewed, with a focus on mechanical activation. Additionally, the milling processes utilized for BCZT synthesis and sintering, as well as water-based sustainable processing, are analysed. The assessment concludes with the promise of emerging uses in biotechnology for medical purposes.