Process for making ceramic, mineral, and metal beads from powder

A method of preparing ceramic beads comprising:

• obtaining a slip comprising a quantity of powder selected from hydroxyapatite, tricalcium phosphate, calcium sulfate, bioglass, and mixtures thereof, a solvent, and one or more grain flours, wherein the powder has a particle size ranging from 10 nm to 500 microns;
• forming droplets of the slip having a droplet size in the range from about 0.1 mm in diameter to about 10 mm in diameter;
• contacting the droplets with a heated oil bath for a sufficient time to form beads;
• separating the beads from the oil;
• removing oil from the surface of the beads;
• drying the beads to remove entrained solvent;
• and
• firing the beads at a temperature sufficient to produce ceramic beads possessing desired physical or chemical characteristics.

A method of preparing beads comprising:

• obtaining a slip comprising a quantity of powder, a solvent, and an organic binder, wherein the powder is selected from metal powders, ceramic powders, mineral powders, and mixtures thereof;
• forming droplets of the slip;
• contacting the droplets with heated oil for a sufficient time to form beads, said heated oil having a temperature of at least 95° Celsius;
• separating the beads from the oil;
• and
• firing the beads at a temperature sufficient to produce beads possessing desired physical or chemical characteristics.

A method of preparing beads comprising:

• obtaining a slip comprising a quantity of powder, a solvent, and an organic insoluble binder, wherein the powder is selected from metal powders, ceramic powders, mineral powders, and mixtures thereof;
• forming droplets of the slip;
• evaporating at least a portion of the solvent by contacting the droplets with heated oil for a sufficient time to form beads;
• separating the beads from the oil;
• and
• firing the beads at a temperature sufficient to produce beads possessing desired physical or chemical characteristics.

A method of preparing beads comprising:

• obtaining a slip comprising a quantity of powder having a mean diameter of greater than 100 microns, a solvent, and an organic insoluble binder, wherein the powder is selected from metal powders, ceramic powders, mineral powders, and mixtures thereof;
• forming droplets of the slip;
• contacting the droplets with heated oil for a sufficient time to form beads;
• separating the beads from the oil;
• and
• firing the beads at a temperature sufficient to produce beads possessing desired physical or chemical characteristics.