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High-Performance Polymer-derived Ceramics in LCD 3D Printing.

H Yazdani Sarvestani1, V Karamzadeh1, A Kulkarni1

  • 1Aerospace Manufacturing Technology Centre, National Research Council Canada, Montreal, QC, H3T 2B2, Canada.

Advanced Science (Weinheim, Baden-Wurttemberg, Germany)
|March 17, 2025
PubMed
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High-strength, lightweight polymer-derived ceramics (PDCs) were fabricated using silicon oxycarbide (SiOC) precursors and 3D printing. This novel method significantly enhances mechanical and thermal properties for advanced applications.

Area of Science:

  • Materials Science
  • Ceramics Engineering
  • Additive Manufacturing

Background:

  • Polymer-derived ceramics (PDCs) offer unique properties but fabrication of complex, high-performance structures remains challenging.
  • Silicon oxycarbide (SiOC) PDCs are attractive for high-temperature applications.
  • Limitations exist in achieving high strength and complex geometries simultaneously with traditional methods.

Purpose of the Study:

  • To demonstrate the fabrication of high-strength, lightweight SiOC PDCs with complex geometries using LCD vat photopolymerization (VPP).
  • To evaluate the influence of feature thickness and pyrolysis temperature on material properties.
  • To develop a printable precursor formulation for advanced ceramic manufacturing.

Main Methods:

  • Utilized liquid crystal display (LCD) vat photopolymerization (VPP) technology with a silicon oxycarbide (SiOC)-precursor formulation.
Keywords:
LCD 3D printinghigh‐temperature pyrolysismechanical propertiesmicrostructural characterizationpolymer‐derived ceramics

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  • 3D printed complex geometries like gyroids and stochastic lattices.
  • Analyzed precursor characteristics using photorheology and thermogravimetric analysis (TGA).
  • Evaluated printed parts via micro-CT scans and mechanical testing after pyrolysis at 800 °C and 1200 °C.

    • Main Results:

    • A printable precursor based on vinyl methoxysiloxane homopolymer (VMM-010) showed rapid curing, low viscosity, and good printability.
    • Successfully 3D printed complex structures with high structural integrity and minimal voids.
    • VMM-based PDC lattices achieved specific compressive strengths up to 9.4 MPa/(g cm³), a 50-fold improvement over controls.
    • Demonstrated exceptional high-temperature stability, maintaining integrity after 2 hours at 1500 °C.
    • Compositional analysis indicated lower free carbon and enhanced ceramic phase formation.

    Conclusions:

    • The VMM-010 precursor formulation is highly suitable for LCD 3D printing of high-performance SiOC PDCs.
    • This approach enables the scalable and reliable fabrication of complex ceramic structures with superior mechanical and thermal properties.
    • The developed PDCs hold significant potential for demanding applications in aerospace, automotive, and biomedical fields.