Embedded 3D Printing of Architected Ceramics via Microwave-Activated Polymerization

Light- and ink-based 3D printing methods have vastly expanded the design space and geometric complexity of architected ceramics. However, light-based methods are typically confined to a relatively narrow range of preceramic and particle-laden resins, while ink-based methods are limited in geometric complexity due to layerwise assembly. Here, embedded 3D printing is combined with microwave-activated curing to generate architected ceramics with spatially controlled composition in freeform shapes. Aqueous colloidal inks are printed within a support matrix, rapidly cured via microwave-activated polymerization, and subsequently dried and sintered into dense architectures composed of one or more oxide materials. This integrated manufacturing method opens new avenues for the design and fabrication of complex ceramic architectures with programmed composition, density, and form for myriad applications.

Hierarchically Porous Ceramics via Direct Writing of Binary Colloidal Gel Foams

Hierarchically porous ceramics with a high specific surface area and interconnected porosity may find potential application as particulate filters, catalyst supports, and battery electrodes. We report the design and programmable assembly of cellular ceramic architectures with controlled pore size, volume, and interconnectivity across multiple length scales via direct foam writing. Specifically, binary colloidal gel foams are created that contain entrained bubbles stabilized by the irreversible adsorption of attractive alumina and carbon (porogen) particles at their air-water interfaces. Composition effects on foam ink rheology and printing behavior are investigated. Sintered ceramic foams exhibited specific permeabilities that increased from 2 × 10^-13 to 1 × 10^-12 m² and compressive strengths that decreased from 40 to 1 MPa, respectively, with increasing specific interfacial area. Using direct foam writing, 3D ceramic lattices composed of open-cell foam struts were fabricated with tailored mechanical properties and interconnected porosity across multiple length scales.

Ultrasonic bandgaps in 3D-printed periodic ceramic microlattices

The transmission of longitudinal ultrasonic waves through periodic ceramic microlattices fabricated by Robocasting was measured in the 2-12MHz frequency range. It was observed that these structures (scaffolds of tetragonal and hexagonal spatial arrangements with periodicity at length-scales of ∼100μm) exhibit well-detectable acoustic band structures with bandgaps. The locations of these gaps at relatively high frequencies were shown to be in close agreement with the predictions of numerical models, especially for tetragonal scaffolds. For hexagonal scaffolds, a mixing between longitudinal and shear polarizations of the propagation modes was observed in the model, which blurred the matching of the calculated band structures with the experimentally measured bandgaps.