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Additive Manufacturing of Functionally Graded Ceramic Materials by Stereolithography

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Structured Polymer-Derived Ceramic Composites via Near-Infrared Thermal Stereolithography.

Evelyn Wang¹, Shruti Gupta², Charles J Rafalko²

¹Department of Chemical Engineering, Michigan State University, East Lansing, Michigan 48824, United States.

ACS Applied Polymer Materials

|July 31, 2025

Summary

This summary is machine-generated.

Near-infrared thermal stereolithography enables printing advanced polymer-derived ceramic composites. This method overcomes limitations of UV printing for high-performance, lightweight ceramic materials.

Keywords:

3D NIR thermal SLA additive manufacturing mechanical properties polymer-derived ceramic silicon carbide

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Area of Science:

Materials Science
Additive Manufacturing
Ceramic Engineering

Background:

Traditional ultraviolet (UV) stereolithography (SLA) faces challenges with composite resins, including limited light penetration and low particle loadings.
These limitations hinder the fabrication of polymer-derived ceramic (PDC) composites with desirable properties.

Purpose of the Study:

To develop a near-infrared (NIR) thermal SLA technique for printing 2.5D-structured PDC composites.
To overcome the limitations of UV-based printing for high SiC particle loading in PDC composites.

Main Methods:

Utilized NIR laser for spatially controlled thermal energy delivery, inducing localized polymerization in a reactive resin pool.
Employed polymer infiltration and pyrolysis (PIP) for postprocessing to densify and strengthen printed samples.
Incorporated a preceramic polymer to form a Si-O-Cₓ support network for structural integrity during processing.

Main Results:

Achieved a flexural strength of 74.3 ± 13.7 MPa and a density of 2.31 g/cm³ after 5 PIP cycles.
Fabricated 2.5D lattice designs, including honeycomb structures with a compressive strength of 32.8 ± 11.2 MPa at a low effective density of 1.07 g/cm³.
Successfully printed PDC composites with high SiC particle loadings, overcoming previous material limitations.

Conclusions:

NIR thermal SLA is a viable method for fabricating high-performance 2.5D PDC composites.
The developed technique offers improved mechanical properties and enables lightweight structural designs.
This approach expands the possibilities for advanced ceramic composite manufacturing.