The Advanced Manufacturing Research Institute (AMRI) of the National Institute of Advanced Industrial Science and Technology(AIST) successfully consolidate α-Al₂O₃ fine powder on the metal substrate at room temperature without binder and firing, for forming the ceramic thick layer, using Aerosol Deposition(AD) method.

It was discovered that the materials particles were fractured and deformed into 10 to 30 nm nano-crystallite size particles during the impact with the substrate. As the result of fracture, the activation of newly formed particles surfaces was occurred stimulating the inter-particle bonding and resulting the formation of very dense nano- crystal structure. Uniform deposition on metal substrate over a 200 mm square area was achieved. α-Al₂O₃ thick layer has fine mechanical and electrical properties as same as that of the bulk sintered material.

This process represents a technological breakthrough, in as much as wide ranging applications are anticipated, such as the use of moderately priced raw material particles, currently used for ceramic processing, to form nano-structured ceramic films, although the conventional sintering process of over 1000°C is not required while achieving the hardness and density equal to ceramics sintered in bulk at high temperatures.