Used for decades in the aerospace industry for its strength, light weight and resistance to heat, ceramics are now moving into the realm of 3D printing on a larger scale than ever before. California-based HRL Laboratories LLC, has created a process to 3D print a “pre-ceramic” resin in almost any size or shape with stereolithography. The resin prints like other 3D printables, but is then fired in a high-temperature kiln which increases its density and enables it to perform like traditionally produced ceramics. Once fired, the material is able to withstand temperatures of 1700° C, and has almost zero porosity.

3D printed ceramic is heated to increase its strength.Because current 3D printed ceramics are made with a sintering powder material, weak, porous products with low resistance to heat are often the result. The new process enables the manufacture of large-scale parts to exhibit the same, or better, mechanical strength as traditionally created ceramic parts. 3D printing also allows for a geometrical flexibility that has not been achieved in the ceramics manufacturing process to date.

The HRL team has also had success producing the material with self-propagating photopolymer waveguide prototyping. The process can generate parts in minutes. The work potentially enables 3D printing of lighter and more efficient jet engine turbines, as well as printed parts for the exterior of jets.

The pre-ceramic resin is a silicon oxycarbide ceramic. In addition to heat resistance, it is resistant to abrasion and corrosion. Beyond aerospace, the team says the material may find applications in electronics and microelectromechanical systems. By adjusting the makeup of the resin, the team can create a variety of ceramic materials each with tailor-made mechanical properties.