Researchers at HRL Laboratories have demonstrated an approach to additively manufacture ceramics that overcomes the limits of traditional ceramic processing and enables fabrication of high-temperature, high-strength ceramic components. HRL Senior Chemical Engineer Zak Eckel and Senior Chemist Dr. Chaoyin Zhou invented a resin formulation that can be 3D printed into parts of virtually any shape and size. The printed resin can then be fired in a high-temperature kiln, converting it into a high-strength, fully dense ceramic. The resulting material can withstand temperatures in excess of 1,700°C and exhibits strength 10 times higher than similar materials.

The ceramic can withstand temperatures in excess of 1,700°C. Image credit: HRL Laboratories/Dan Little Photography.The ceramic can withstand temperatures in excess of 1,700°C. Image credit: HRL Laboratories/Dan Little Photography. Ceramics are generally much more difficult to process than polymers or metals because they cannot be cast or machined easily. Traditionally, ceramic parts are consolidated from powders by sintering, which introduces porosity and limits both achievable shapes and final strength.

"With our new 3D printing process, we can take full advantage of the many desirable properties of this silicon oxycarbide ceramic, including high hardness, strength and temperature capability as well as resistance to abrasion and corrosion," says program manager Dr. Tobias Schaedler.

The company says it believes the process and material could be used in a range of applications, from the manufacturing of large components in jet engines and hypersonic vehicles to the fabrication of intricate parts in microelectromechanical systems and electronic-device packaging.

HRL is seeking a commercialization partner for the technology.

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