Researchers develop 3D printing process for high-performance ceramics at low temperatures

A team of researchers led by Penn State University is working on a new process for manufacturing high-performance ceramics using 3D printing. The project, funded by the US Department of Defence with 4.5 million dollars, aims to produce ceramic materials at significantly lower temperatures than previously possible.

Robert Hickey, Associate Professor of Materials Science at Penn State, explains the main problem: ‘The high temperatures and high energy requirements of ceramic manufacturing are currently a major obstacle, especially for 3D printing.’ Conventional processes require the entire material to be heated, which can lead to material losses of up to 50% and changes to the component geometry.

The research team’s approach uses high-power lasers to trigger chemical reactions in polymer precursor materials. This method should enable rapid densification into hardened ceramics without large-scale heating. ‘We are investigating how we can convert polymers into ceramics using light, with the ultimate goal of producing high-performance ceramics using 3D printing,’ says Hickey.

The project combines experimental and theoretical approaches. The results will be incorporated into simulations, which in turn will drive the development of new polymer precursors. Benjamin Lear, Professor of Chemistry at Penn State, emphasises the importance of the interdisciplinary team: ‘Penn State, Michigan State, MIT and USC are ideal partners in this work and already have existing connections between computational and experimental researchers on this team.’

The research could have significant implications for the development of advanced hypersonic vehicles. Adri van Duin, professor of mechanical engineering at Penn State, explains: ‘This programme will open new avenues for additive manufacturing of ceramic materials across a range of high-temperature metal carbides and silicon-based ceramics.’