Symposium CB
ABSTRACTS
Session CB-1 Recent advances in additive manufacturing technologies for ceramics, glasses and composites
CB-1:IL01 Additive Manufacturing of Glasses and Glass-Ceramics
T. MORITZ, J. SCHILM, A. ROST, E. SCHWARZER-FISCHER, L. GOTTLIEB, A. MÜLLER-KÖHN, Fraunhofer Institute for Ceramic Technologies and Systems, Dresden, Germany
Ceramic additive manufacturing (AM) methods for dense components rely on inks, pastes, suspensions, thermoplastic feedstocks, or filaments to achieve homogeneous particle packing in the green part, enabling complete densification during sintering. Key AM methods include Vat Photopolymerization (VPP), using photocurable suspensions applied layer by layer, and Multi Material Jetting (MMJ), depositing low-viscosity thermoplastic feedstocks drop by drop. Both technologies were applied for AM of glass and glass-ceramic functional components. Compared to melt shaping, sintering operates at temperatures several hundred Kelvin lower, saving energy, reducing the CO2 footprint, and enabling the incorporation of functional pigments into the glassy matrix, which would degrade at higher temperatures. This allowed the production of complex-shaped glass components with properties such as electrical conductivity, coloration, biocidal activity, and luminescence. Additionally, AM was used to fabricate glass-ceramic components with either extremely low thermal expansion or high mechanical strength as cost-effective alternatives to structural ceramics. The presentation will discuss development results, advantages, and limitations of AM glass and glass-ceramic components compared to conventional shaped components.
CB-1:IL02 New 3D Printing Process for Ceramics Based on Dynamical Colloidal Assembly
M. CERBELAUD, G. MICHAUD, F. DUMAS-BOUCHIAT, F. ROSSIGNOL, A. VIDECOQ, Univ. Limoges, CNRS, IRCER, UMR 7315, Limoges, France
The fabrication of ceramic parts with complex shapes using simple shaping processes remains challenging today. One of the simplest methods is the direct ink writing, which consists of extruding a paste that has been formulated in advance to have the appropriate rheological properties. The formulation of this paste remains the key point for this process. Instead, here we will present a new extrusion process called Colloidal Assembly Writing (CAW) which uses simple stable suspensions containing few or no organic additives. The principle of this process consists of individually conveying two suspensions into a microfluidic channel where the particles they contain can heteroaggregate to form a cohesive filament that can be extruded. The importance of hydrodynamic effects induced by shear in microfluidic channels on heteroaggregated structures will be discussed, in particular using numerical simulations. We will also show the possibilities offered by this process, in which filament formation is dynamic.
CB-1:IL03 Catalytic Function-driven Meta-structual Design and 3D Printing of Porous Ceramics
XIAOYONG TIAN, CUNBAO HUO, Xi'an Jiaotong University, Xi’an, China
Conventional packed-bed catalysts suffer from single-scale porosity, insufficient mechanical strength, and suboptimal mass transfer. Inspired by the lung’s fractal structure, we propose a design and 3D-printing method for gradient meta-structural catalysts by integrating LaFe₀.₅Ni₀.₅O₃ (LFN) perovskite with pseudo-boehmite, achieving ultralow pressure drop and high catalytic efficiency. Computational fluid dynamics and reaction simulations guide the design of uniform and gradient catalysts with hierarchical woodpile channels (0.5–3 mm). The gradient design theoretically enhances flow velocity and hydrogen production by 1.5-fold and 1.1-fold, respectively, compared to homogeneous catalysts. The fabricated catalysts feature a gradient multi-peak pore distribution (9.32, 103.75 nm), regionally modulated unit cell sizes and LFN content (11–35%), and a 78.7-fold higher specific surface area (102.26 m² g⁻¹) with 8.48 MPa compressive strength. In dry methane reforming, they achieve 82.13% CH₄ conversion and 9.69 mmol g⁻¹ syngas yield, surpassing conventional packed beds by 10% in efficiency. This work couples mass transfer and catalysis via gradient hierarchical pores and tailored flow dynamics, offering a robust, high-efficiency catalyst design paradigm.
CB-1:IL04 Strategies to Achieve Higher Mechanical Strength in Thermoplastic MExAM 3D Printed Ceramics Structures
F. CLEMENS1, P. JUSTEN1,2, E. MONTAKHAB1, N. THOMAS2, 1Empa - Swiss Federal Laboratories for Materials Science and Technology, Dübendorf, Switzerland; 2Hochschule Koblenz, WesterWaldCampus, Höhr-Grenzhausen, Germany
A key drawback of thermoplastic material extrusion in additive manufacturing is the occurrence of printing defects, which reduce mechanical strength compared to pressed parts. This study explores combining additive and subtractive methods to produce defect-free structural ceramic components. Zirconia discs were printed using a ceramic injection molding (CIM) feedstock and a 3D printer with a milling head. Some discs underwent contour and surface milling between printing steps. Mechanical performance was evaluated via biaxial flexural strength tests using ring-on-ring and ball-on-three balls setups. The hybrid method significantly improved strength—by a factor of 1.6—and enhanced the Weibull modulus. Milling improved surface quality and eliminated defects at the interface between the outer shell and inner regions, though this did not further affect strength. The ball-on-three balls test yielded the highest values, with flexural strength reaching 627 MPa and a Weibull modulus of 9.6.
CB-1:IL05 Artificial Intelligence and Automatization in Additive Manufacturing for 3D Printing Big Ceramic Parts and Big Series of Parts
E. LOURADOUR, R. GAIGNON, CEO 3DCERAM SINTO, Limoges, France
The integration of artificial intelligence (AI) and full-process automatization in additive manufacturing (AM) represents a transformative paradigm to reach the new era of manufacturing. By addressing key challenges such as design complexity, printing parameters optimization, and production scalability, AI-driven solutions enable real-time decision-making and predictive analytics across the entire AM workflow. Automatization enhances production efficiency through seamless coordination of pre-production, in-situ monitoring, and post-processing, reducing waste and improving product quality. Together, these advancements position AM as a pivotal solution for manufacturers, offering unprecedented flexibility, cost-effectiveness, and sustainability. The adoption of AI and automation in AM not only accelerates innovation but also bridges the gap between traditional manufacturing and the digital era, making it an indispensable tool for the future of production systems.
CB-1:IL06 Extrusion Based 3D Printing of Geopolymer and its Composites
PEIGANG HE, DECHANG JIA, YU ZHOU, Institute for Advanced Ceramics, Harbin Institute of Technology, Harbin, China
3D printing of geopolymers with desirable patterns, compositions, and properties holds great promise for sustainable construction materials, porous adsorbent, and high-temperature ceramics. Current research mainly focuses on the rheological behavior of geopolymer slurry, 3D printing of geopolymer with high resolution, and hierarchical structures. In this paper, we reported a universal method to realize direct ink writing of geopolymer materials regardless of alkaline cation types. Then geopolymer of bionic structures were prepared and strengthening and toughening mechanisms were investigated. Current results proved that 3D printing together with bionic-structure designing provide a novel method for the composites of lightweight, high strength & toughness, and superior impact resistance, which would lead to a resurgence of interest in new lightweight and reliable structure design strategies.
CB-1:L07 Additive Manufacturing of Continuous-fiber Reinforced CMCs
R. GIOMETTI, A. DE MARZI, G. FRANCHIN, P. COLOMBO, Department of Industrial Engineering, Università degli Studi di Padova, Padova, Italy; A. DE ZANET, A. KUMAR, Innovation Hub - Materials Labs, Leonardo SpA, Roma, Lazio, Italy
Ceramic matrix composites (CMCs) have been developed for high-temperature and harsh corrosive environments, including ultra-high temperatures and extreme loading. High-strength fiber reinforcements in CMCs overcome ceramics’ brittle behavior, preventing catastrophic failure under stress. Additive Manufacturing (AM) technologies enable complex geometries, such as lattice structures, lightweight components with ordered porosities, and customized parts. The combination of AM and CMCs is significant for industries that require materials with exceptional mechanical, thermal and environmental properties to be formed into complex shapes. In contrast to the traditional infiltration-based methods for the fabrication of CMCs, we present a process to produce crack-free continuous carbon fiber-reinforced ceramics matrix composites in a single heating step, without the need of further densification or infiltration processes. These composites exhibit graceful failure and enhanced toughness compared to non-reinforced samples, with relatively low mass loss and shrinkage.
CB-1:L08 Continuous Layer Deposition for the Additive Manufacturing of Ceramics by Layerwise Slurry Deposition.
J. GUNSTER, A. ZOCCA, Bundesanstalt für Materialforschung und -prüfung (BAM), Berlin, Germany
Powder bed technologies are among the most successful additive manufacturing techniques. However, the application of these techniques to ceramics has proven challenging due to the difficulty of depositing homogeneous powder layers when using fine powders. Layerwise slurry deposition (LSD) has therefore been developed as a deposition method that enables powder bed AM technologies to be used with advanced ceramic materials. In LSD, a ceramic slurry is deposited in layers using a doctor blade and then dried to produce a highly compacted powder. This process can handle very fine submicron powders with low organic content, and the dense powder bed provides excellent support for the manufactured parts. The latest development in this technology demonstrates the ability to print ceramic parts continuously by depositing a layer on a rotating platform, with a powder bed growing in a spiral motion. The unique mechanical stability of the layers in LSD printing enables a powder bed several centimetres thick to be built up without lateral support. Continuous layer deposition achieves productivity levels more than ten times higher than linear deposition, approaching a build volume of one litre per hour.
CB-1:L09 Laser Printing, Densification and Properties of Silicon Carbide Ceramic Composites
JIE YIN, Shanghai Institute of Ceramics, Chinese Academy of Sciences, Shanghai, China
Laser printing is a promising technique for the preparation of complex-shaped SiC composites. High-quality powders are critical for high-precision laser printing. In this work, we combined selective sintering and liquid silicon infiltration for a higher-efficiency and higher-performance-component fabrication. Precursor infiltration and pyrolysis techniques were also introduced for enhance the properties of the printed green bodies before sintering. We prepared complex-structured composites therefrom. The relationship between microstructure tailoring and mechanical as well as thermal performance were investigated.
Session CB-2 New additive manufacturing approaches, including multi-material and hybrid printing technologies
CB-2:IL10 Pressure-less Spark Plasma Sintering of Ceramics with Graphene-like Networks
A. KOCJAN, N. BHOOTPUR, Jozef Stefan Institute, Ljubljana, Slovenia
Ceramic matrix composites (CMCs) with carbon-like nanofillers exhibit improved mechanical and electrical properties. However, the homogeneous incorporation of nanofillers is challenging. Pressure-assisted Spark Plasma Sintering (SPS) favours the production of CMCs, but facilitates undesired anisotropy in properties due to filler alignment, especially in the case of graphene and/or MXenes (perpendicular to the pressure). Also, SPS is limited to simpler geometries, thus not allowing sintering for additively manufactured (AM), complex-shaped, multi-material ceramics. Multi-material AM could benefit in exploiting the functionalisation of these nanofillers via a pressure-less rapid sintering approach such as ultra-high temperature sintering (UHS) and pressureless SPS (pSPS). These can deliver increased heating rates, which were shown to be successful in consolidation of AM ceramics with refined microstructures. We studied the rapid sintering (pSPS and UHS) of oxide ceramic matrices with homogeneously dispersed cellulose nanofibers (CNF), which are, in contrast to carbon-like nanofillers, obtained from plants, hydrophilic and easier to process. It was shown that CNF can be in situ transformed during pSPS into few-layer graphene-like (FLG) networks not prone to anisotropic alignement.
CB-2:IL11 Advancing Ceramic 3D Printing: From Material feedstock to Powder Bed Fusion
D. GROSSIN1, A. MONTÓN1, G. URRUTH1,2, E. ÖZMEN1, M. EID ABDELMOULA3, P. NAVARRETE-SEGADO1,4, F. MAURY1, P. LENORMAND1, D. MAURY2, G. BERTRAND1, C. FRANCES4, M. TOURBIN4, G. KÜÇÜKTÜRK3, 1Univ. Toulouse, Toulouse-INP, CNRS, CIRIMAT, France; 2Marion Technologies, France; 3Gazi University, Turkey; 4Univ. Toulouse, Toulouse-INP, CNRS, LGC, France
Additive manufacturing of ceramics is progressing rapidly toward the production of dense, complex, and high-performance components. This talk will highlight the main achievement, among powder bed fusion (PBF) has emerged as a promising route for producing ceramic parts. The success of this process strongly depends on the control of the feedstock, including powder composition, particle size distribution, surface chemistry, and flowability. Tailored oxide (alumina, zirconia), calcium phosphate (Hydroxyapatite) and non-oxide (silicon carbide) powders have been developed to ensure homogeneous layering and efficient energy absorption during printing. Advances in laser–material interaction and printing parameters such as powder spreading, powder compaction, laser scanning parameters (speed, hatch distance, and power) now allow the fabrication of fine-featured structures with controlled porosity and microstructure. Optional post-processing steps such as thermal treatment further enhance mechanical strength and reliability. These developments demonstrate that optimizing the feedstock–process relationship is essential to extend the capabilities of ceramic 3D printing and to unlock new applications in biomedical, energy, and aerospace fields.
CB-2:IL12 Ceramic 3D Printing Accelerates Electromagnetic Wave Absorption from Materials to Structures
RUJIE HE, Beijing Institute of Technology, Beijing, China
As 3D printing technology and ceramic material advance, significant progress has been achieved in the field of 3D-printed ceramic materials for electromagnetic wave absorption (EMWA), transitioning from simple material fabrication to complex structure creation. This report will summarize the key advancements in ceramic materials and structures fabricated by 3D printing for EMWA. Despite significant progress, the limitations that remain in 3D-printed ceramic materials and structures for EMWA are highlighted, and future development tendencies are also identified. This report aims to motivate further development and application of 3D-printed ceramic materials and structures. for EMWA.
CB-2:L13 Dense ZrB₂ via Carboxylmethylcellulose-based Direct Ink Writing and UHS-SPS
F. LEBAS, S. MARINEL, C. MANIÈRE, Université Caen Normandie, ENSICAEN, CNRS, Normandie Univ, CRISMAT UMR6508, Caen, France
Zirconium diboride (ZrB2) is an ultra-high temperature ceramic (UHTC) with potential for applications in extreme environments. However, both shaping and sintering remain significant challenges. Additive manufacturing provides promising opportunities for producing complex ZrB2 components, but requires the development of suitable formulations. At the same time, sintering ZrB2 is difficult due to its low diffusivity and high oxidation sensitivity In this work, we developed a ZrB2 suspension based on cationic carboxymethylcellulose (CMC), which enables the printing of complex and highly self-supporting parts by providing optimized rheological properties, ensuring both flowability and dimensional stability. A dilatometer study on specific sintering additives was carried out to enhance densification up to 2200°C. Finally, shaping and densification were further explored through the use of UHS-SPS, opening new perspectives for the processing of dense ZrB2 ceramics.
CB-2:L14 Predicting 3D-Printed Sintering Distortions Using Combined FEM and Deep Learning Approaches
C. MANIÈRE, Université de Caen Normandie, CRISMAT, Normandie University, ENSICAEN, CNRS, Caen, France
Sintering large 3D-printed parts with overhangs is highly challenging due to their strong susceptibility to distortion. To define suitable sintering conditions, several strategies can be considered, such as adjusting the sintering cycle or using sacrificial supports. However, purely experimental optimization would require long campaigns of printing and sintering with numerous trial-and-error iterations before identifying optimal conditions. Finite Element Method (FEM) simulations can be used to virtually perform these optimization steps. Yet, the geometric complexity of the parts demands fine meshing, and large overhangs may lead to high deformation levels that cause numerical divergence or computation times exceeding those of the experiment itself. To overcome these limitations, we propose a hybrid approach that combines FEM and deep learning. FEM simulations are first conducted on simple geometries to generate a large synthetic dataset representing a wide range of mechanical solicitations during sintering. This dataset is then used to train a deep learning model capable of predicting whether a given 3D-printed shape will withstand sintering or fail, based on minimal FEM input. This strategy significantly accelerates the identification of viable sintering conditions.
CB-2:L15 Enhancing Mechanical and Biological Performance of Polymer-Derived Ceramics through LCD 3D Printing and Nanofillers
V. KARAMZADEH1, H. YAZDANI SARVESTANI1, A. SOHRABI-KASHANI1, A. KULKARNI1, T. LACELLE2, M.B. JAKUBINEK2, B. ASHRAFI1, 1Aerospace Manufacturing Technologies Centre, National Research Council Canada, Montreal, QC, Canada; 2Division of Emerging Technologies, National Research Council Canada, Ottawa, ON, Canada
Ceramic materials possess exceptional strength and thermal stability but are limited by brittleness and processing constraints. Polymer-derived ceramics (PDCs) offer greater design freedom, enabling complex geometries unattainable with traditional methods. This study presents a cost-effective route for fabricating reinforced PDCs using low-cost liquid crystal display (LCD) 3D printing combined with nanofiller integration. Silicon nitride and alumina nanoparticles were incorporated into a silicon oxycarbide precursor (SPR-684) matrix to enhance mechanical properties. Optimized photocurable formulations were printed into gyroid and lattice structures and converted to ceramics through pyrolysis. Varying nanofiller loadings (0.2–1 wt%) were evaluated for effects on density, microstructure, and mechanical performance. The best compositions achieved remarkable gains, up to 2060 % in toughness, 20 % in stiffness, and 900 % in compressive strength. Cytotoxicity assays confirmed high cell viability and adhesion, while compressive strength values approached those of human trabecular bone, indicating suitability for load-bearing implants. This LCD 3D printing strategy enables affordable, precise, and biocompatible ceramic fabrication for next-generation biomedical applications.
CB-2:IL16 Development of a Hybrid and Multimaterial Additive Process to Realize AlN / Mo Multilayer Ceramic Component
V. PATELOUP, A. JUNGER, IRCER UMR CNRS 7315, Limoges, France; N. VENET, Thales Alenia Space, Toulouse, France
High Temperature Co-fired Ceramics (HTCC) are widely used for electronic packaging in order to obtain conductive metallic networks embedded in a ceramic subtrate. Thus In the case of space applications, contraints of high thermal conductivity, low dielectric constant and complex metallic network are added. In order to propose an efficient manufacturing process from this type of components, presented works propose a hybrid additive manufacturing approach for printing HTCC. An home made SLA/robocasting system has been developed to print AlN substrate and deposit Mo tracks inside it, with a target resolution of 50 µm in line width and spacing. Metal ink formulation and printing strategies are defined to achieve precise and defect-free circuits. Tracks of 100 µm width × 10 µm thickness × 60 µm gap are achieved. Co-firing in a reducing atmosphere produce dense AlN, conductive Mo networks within AlN, enabling reliable HTCC packages. Hyper-frequency component are fabricated and characterized, confirming the potential of this hybrid process as an alternative to conventional HTCC routes. This work is carried out at IRCER in collaboration with Thales Alenia Space, with support from the French Defence Innovation Agency (AID).
CB-2:L17 Combining High-throughput Methods and Robocasting of AZO-ZrO₂ Structures for Compositional Screening and Process Optimization
L. WAHL, E. WOLF, T. FEY, Department of Materials Science (Glass and Ceramics), University of Erlangen-Nürnberg, Erlangen, Germany
Aluminum-doped zinc oxide (AZO) is a material known for its high electrical conductivity and optical transparency. In contrast, zirconia (ZrO₂) is a high-strength, electrically insulating material with excellent mechanical properties. By combining AZO with ZrO₂, ceramic composites with tunable electrical properties and improved mechanical performance can be developed. Robocasting is an additive manufacturing technique offering the possibility to shape various materials into three-dimensional complex shapes. High viscous pastes are extruded through fine nozzles and deposited layer by layer. Another advantage of the robocasting process is the possibility of multi-material printing, facilitating the combination of different materials, resulting in complex structures with spatially varying properties. This work focuses on the printing of AZO/ZrO2 core-shell structures. The difficulty that arises when working with different materials is adapting the properties, such as shrinkage, to avoid crack formation or delamination. In this work, high-throughput methods were used to analyze the entire compositional range and investigate these properties quickly, while minimizing human interaction time. The results were then linked to the robocasting process to improve the printing results.
CB-2:L18 Optimization of z-leveling in FDM by Deep Learning
J. GERHARDS, F. ROSSIGNOL, IRCER, UMR CNRS 7315, University of Limoges, France
3D printing allows custom manufacturing and rapid prototyping, making processes more accessible to a wide range of users. Despite this progress, printers utilizing micro-extrusion techniques like FDM often encounter challenges with print quality and speed, primarily due to a lack of advanced features. At first, a significant challenge lies in the correct adjustment of the Z-leveling, which is strongly dependent on the feedstocks used and the processing parameters (printing strategy and speed). For instance, during intricate printing maneuvers—such as sudden stops, accelerations —the release of elastic energy can lead to defects in the final product. Here, we will show, based on the use of a very basic FDM printer, how deep learning can help optimizing the z-leveling far beyond the intrinsic capability of the hardware attached to the printer, increasing the precision of almost an order of magnitude. In addition, we will explain how the neural network can be "engineered" to reach such a target with limited computing requirements so that to be operated on devices like a Rasberry Pi.
This research is conducted as part of the RUBIS flagship of the French national initiative on Artificial Intelligence applied to materials science & processes (PEPR DIADEM, ANR-22-PEXD-0010).
CB-2:L19 Direct Ink Writing of Sphene (CaTiSiO5) Core-Shell Structures with Enhanced Structural and Functional Properties for Bone Substitutes
V. GASTALDI, L. BIASETTO, University of Padova, Padova, Italy; D. BELLUCCI, V. CANNILLO, University of Modena and Reggio Emilia, Modena, Italy
Co-axial 3D extrusion represents a versatile Multi-Material Additive Manufacturing (MMAM) approach for producing components with customized structural and functional architectures. This technique enables the integration of different materials (dense/porous or ductile/brittle) within a single component, allowing the development of hybrid systems with tailored performance. In this study, sphene (CaTiSiO₅) core–shell architectures were fabricated using a one-step co-extrusion nozzle through Direct Ink Writing. Two configurations were investigated: a dense sphene core with a porous shell, and a metallic core combined with a porous sphene shell. Owing to the proven bioactivity of sphene, the ceramic shell was selected for scaffolds aimed at bone regeneration. The work addresses key processing challenges, including ink optimization, debinding, sintering, and mitigation of differential volumetric shrinkage between coupled materials. The resulting core–shell structures were characterized in terms of mechanical behavior, morphology, interfacial integrity, and preliminary biocompatibility, demonstrating the potential of co-axial extrusion as a route toward next-generation, functionally graded biomedical implants.
CB-2:IL20 Microwave Volumetric Additive Manufacturing: Revolutionizing Ceramic Additive Manufacturing
D. POST GUILLEN1, S. MUKHERJEE2, K. STRONG3, C. DECHANT1, E. BUTTERWORTH1, C. ICENHOUR1, E. ROSENBERG2, J. VANDENBRANDE2, N. BELL3, JO. SCHWARTZ2, 1Idaho National Laboratory, Idaho Falls, ID, USA; 2Lawrence Livermore National Laboratory, Livermore, CA, USA; 3Sandia National Laboratories, Albuquerque, NM, USA
We are developing a fast, scalable volumetric additive manufacturing (VAM) system using a high-power microwave beamforming antenna array to deliver localized energy to 3D volumes. This system advances ceramic additive manufacturing by enabling detailed, large-scale prints through deeper thermal energy delivery into opaque, particle-laden resins compared to photonic approaches. Current efforts focus on improving part fidelity with experimental beamforming systems and developing microwave absorptive resins for rapid, focused curing of ceramic materials. Microwave thermal diffusion with ceramic sintering kinetics is simulated within the Multiphysics Object-Oriented Simulation Environment framework to optimize resolution, processing parameters, and scalability. The multiphysics model simultaneously solves for the electromagnetic field, heat generation, and chemical reactions. Future work includes pulsed microwave simulations and coupling with fluid and solid mechanics to account for resin viscosity, convection effects, and mechanical strength. This holistic approach, which combines innovations in ceramic chemistry, microwave beamforming, and multiphysics computational modeling, aims to address the limitations of current ceramic VAM technologies.
CB-2:IL21 Development of Multi-functional Components for Ultra-High Vacuum Applications Using Multi-material 3D Printing
L. BIASETTO, C. BOARETTI, Department of Industrial Engineering, University of Padova, Padova, Italy; N. DELERUE, Universitè Paris-Saclay, CNRS/IN2P3, Orsay, France
Multi-material 3D-printed components represent a major frontier in additive manufacturing due to their wide potential across electronics, aerospace, defense, nuclear, and biomedical sectors. Combining metallic and ceramic phases in a single part enables the precise tuning of structural and functional properties to meet specific application requirements. Despite these advantages, several challenges remain before achieving the level of process standardization required for industrial implementation, particularly in terms of interfacial bonding, porosity control, and material uniformity. In this work, we present our experience in fabricating 316L–Al₂O₃ composite flanges designed for beam alignment in particle accelerators. A multi-extrusion 3D printing system was employed using both commercial and in-house Al₂O₃ pellets to minimize defects and residual porosity. The final objective is to develop components suitable for Ultra-High Vacuum (UHV) environments, demonstrating the feasibility of multi-material additive manufacturing for advanced scientific applications.
CB-2:L22 Green State Joining of Ceramic Components Fabricated by DLP Additive Manufacturing
D. MELANSON, G. BOUBNOVA, S. CLEMENS, E. MOREAU, K. PLUCKNETT, Dalhousie University, Dept. of Mechanical Engineering, Halifax, Nova Scotia, Canada
Digital light processing (DLP) additive manufacturing allows preparation of complex-shaped ceramic components with high precision. While this is suitable for many applications, there are still scenarios where the joining of parts is desirable. This might include joining dissimilar materials, or when enforcing some form of microstructure design. In the present work, ‘green’ state joining of a range of oxide ceramics is undertaken, including Al2O3-based systems. In this instance, after DLP printing, utilizing a slurry comparable to one or both parts being joined, thermal curing of the printed parts is employed for cross-linking the organic components. This step is followed by removal of the organic constituents and sintering. The effects of joint design and print tolerance, materials pair selection, macro- and microstructure development, and preliminary properties will be discussed.
CB-2:L23 Multi-Material DLP Additive Manufacturing of Al2O3-Based Ceramic Composites
G. BOUBNOVA, S. CLEMENS, A.M. DAVID, E.D. MOREAU, K.P. PLUCKNETT, Dalhousie University, Dept. of Mechanical Engineering, Halifax, NS, Canada; M. HAMIDPOUR, H.Y. SARVESTANI, M. RAHMAT, B. ASHRAFI, Aerospace Manufacturing Technologies Center, National Research Council Canada, Montreal, QC, Canada; M.B. JAKUBINEK, Division of Emerging Technologies, National Research Council Canada, Ottawa, ON, Canada
Photocurable, alumina-based slurries were toughened through incorporation of varying amounts of ceria-stabilized zirconia (Ce-TZP), which were then used to produce multi-layer ceramic components using a dual vat digital light processing (DLP) additive manufacturing system. Following removal of the organic components and sintering, selected material properties were investigated. Monolithic Al2O3 and Al2O3/Ce-TZP samples (with 0 to 10 vol.% Ce-TZP) were printed and subjected to thermal and mechanical tests including dilatometry, Vickers hardness, and nano-indentation. Nano-indentation tests were conducted to evaluate the residual stresses at the interfaces of tri-layer Al2O3 and Al2O3/Ce-TZP based laminates, which were then compared with predictions via finite element modeling. Additionally, preliminary results from strength tests on these tri-layer laminates are presented, highlighting the effects of varying the Al2O3 and Al2O3/Ce-TZP compositions and laminate thicknesses on mechanical performance. These observations underscore key design considerations for the application of AM technologies in the development of advanced ceramic multi-material components.
CB-2:L24 Digital Light Processing of PLA/HA Scaffolds with a Unique Combination of Structural and Compositional Gradient: Design, Fabrication and Characterization
Z. ABBAS1, J. PALLAGANI1, A. LA GATTA2, C. SCHIRALDI2, B. COPPOLA1, P. PALMERO1, 1Politecnico di Torino, Department of Applied Science and Technology, INSTM R.U. Lince Laboratory, Italy; 2Department of Experimental Medicine, Section of Biotechnology, University of Campania “Luigi Vanvitelli”, Naples, Italy
Digital Light Processing (DLP) allows fabricating scaffolds with structural and compositional gradients, able to match the bio-mechanical properties of multi-layer tissues. Uniform dense and gyroid samples as well as structurally graded gyroid scaffolds were designed based on triply periodic minimal surfaces (TPMS) and fabricated by DLP using polylactic acid/hydroxyapatite (PLA/HA) composite slurries. Ultrafine HA powders were added to a commercial PLA resin in different amounts, where the lowest and highest solid loadings were determined on the ground of slurries rheology and printability. Uniform samples were prepared using PLA/HA composite slurries at 0wt%, 35wt% and 55wt% HA. Subsequently, graded samples with different HA loadings were obtained by mixing 35wt% and 55wt% HA slurries, using a multi-head automatic peristaltic pump, gradually achieving intermediate HA loadings corresponding to 42wt% and 48wt%. The effect of HA amount on physical, microstructural and mechanical properties of both dense and gyroid scaffolds were evaluated, and preliminary biological tests proved samples biocompatibility. Finally, a gyroid having a continuous structural gradient and compositional variation was successfully printed. In this way, the feasibility to obtain, in a single printing job.
Session CB-3 Development of novel feedstock formulations
CB-3:IL26 Direct Ink Write of Ultra-High Temperature Ceramic Matrix Composites
D. CALVO, J. YOUNGBLOOD, R. TRICE, Purdue University, School of Materials Engineering, West Lafayette, IN, USA
Results to date for manufacturing carbon-fiber reinforced zirconium diboride (Cf/ZrB2) ultra-high temperature ceramic matrix composites (UHTCMCs) via direct ink writing (DIW) will be presented. The parameters for aqueous slurries were optimized, comprised of zirconium diboride (ZrB2), 10 vol.% pitch-based milled carbon fibers, polymer binder, ammonium polyacrylate dispersant, and varying amounts of carbon-yielding phenolic resin. The effect of phenolic resin additions on ink behavior and suitability for printing was studied via rheological measurements and zeta potential testing. SEM was used to observe fiber integrity after sintering. Four-point bend flexure testing was used to determine flexural strengths as a function of sintering temperature and phenolic additions. Sintered samples will be subject to high-heat flux conditions using an oxy-acetylene torch.
CB-3:L28 Advanced SLA-Based Additive Manufacturing of Lead-Free Piezo-Ceramics: From Powder Synthesis to Functional Devices
I.V. SHISHKOVSKY, Lebedev Physical Institute of RAS, Samara, Russia
We report the development of advanced photopolymerizable feedstocks for SLA-based 3D printing of lead-free piezo-ceramics, including BaTiO₃, KNN, and NBT. Powders were synthesized via hydrothermal, solid-state, and supercritical methods, with controlled morphology, particle size, and optical properties tailored for laser wavelengths of 450–465 nm. Ceramic pastes with up to 55 vol.% loading were formulated and tested for polymerization efficiency, achieving layer curing depths exceeding 100 µm. A custom SLA printer enabled precise deposition (20 µm) and dynamic wavelength adjustment for optimized curing. The sintered parts exhibited high piezoelectric performance (e.g., BaTiO₃ d₃₃ ≈ 148 pC/N), surpassing conventional benchmarks. Feedstock properties were digitized and linked to printing outcomes, forming a predictive database for device design. The feedstocks supported multimaterial printing and internal texturing, enabling fabrication of complex functional structures. This work advances feedstock engineering for ceramic additive manufacturing and establishes a reproducible framework for performance-driven material design.
CB-3:L29 Low-temperature Printable Polysiloxane-based Feedstocks for Extrusion-based Additive Manufacturing of Polymer-derived Ceramics
M. SHAH, T. EDTMAIER, T. KONEGGER, TU Wien, Institute of Chemical Technologies and Analytics, Vienna, Austria; F. BAUER, M. KRACALIK, Johannes Kepler University Linz, Institute of Polymer Science, Linz, Austria; V. PANDEY, A. IVEKOVIC, Jozef Stefan Institute, Department for Nanostructured Materials, Ljubljana, Slovenia
Extrusion-based additive manufacturing (AM) of polymer-derived ceramics (PDCs) provides a versatile route for producing complex ceramic components with tunable architectures and properties. However, the limited printability of preceramic polymers and the structural distortion during pyrolysis remain major challenges. In this work, a low-temperature processable feedstock system was developed using a polysiloxane matrix mixed with an ethylene-vinyl-acetate thermoplastic binder. Compounding, filament extrusion, and printing were carried out below 120 °C. The optimized formulation exhibited homogeneous flow behavior suitable for printing and yielded uniform green bodies with precise dimensional control. While untreated printed parts consistently failed during pyrolysis due to melting-induced loss of structural integrity, a post-printing surface treatment with iron(III) acetylacetonate resulted in adequate shape retention. Dipping times of ≤ 30 s enabled partial surface crosslinking stabilizing the polymer network during the subsequent polymer-to-ceramic transformation at 1000 °C, resulting in a ceramic yield of about 40 %. These results showcase a viable route toward low-temperature extrusion of dimensionally stable PDC structures suitable for extreme environments or harsh conditions.
CB-3:IL30 2PP of Technical Ceramic – What’s Next?
J. MÜLLER-ELMAU1, B. PAUW1, B. RIECHERS1, A. ZOCCA1, JENS GÜNSTER1,2, 1Federal Institute for Materials Research and Testing (BAM), Berlin, Germany; 2Clausthal University of Technology, Institute of Non-Metallic Materials, Clausthal-Zellerfeld, Germany
Volumetric photon-based additive manufacturing technologies like two-photon-polymerization (2PP), Xolography and holographic technologies promise the highest accuracy and dimensional freedom. To transfer the light through the feedstock it needs sufficient transparency. Ceramic particles used for powder processing routes act as scattering sites and therefore hinder the light transmission, unless… The particle size are chosen small enough, roughly 1/10th of the light wavelength, which decrease scattering vastly. The resulting resins are transparent, even with ceramic weight fraction of up to 80%. With two-photon-polymerization the smallest yttria stabilized zirconia structures with a resolution of 500nm and unique mechanical properties were printed. The same feedstock was applied to LCM as layer-by-layer AM-technologies for bigger parts. Hybridizing both technologies enables ceramic parts with microscopic accuracy at macroscopic dimensions. The feedstock was even applied to the volumetric Xolography with the highest transparency requirement so far. What are the next steps? Can those proof-of -concept studies be transferred to industrial applications? How to make the stretch between fundamental research and application-oriented development?
CB-3:IL31 Large Scale Binder Jetting of Ceramics from Waste
H. ELSAYED, P. COLOMBO, Department of Industrial Engineering, University of Padova, Padova, Italy
This study investigates the potential of binder jetting (BJ) for large-scale additive manufacturing of ceramics derived from industrial waste, with a focus on alkali-activated and geopolymeric systems. Geopolymer binders formulated from slag, metakaolin, construction and demolition waste, and waste glass provide a low-carbon, fire-resistant, and durable alternative to conventional cement, aligning with circular-economy and sustainability objectives. A large-scale BJ process was developed to fabricate geopolymer components using a powder bed composed of metakaolin and/or slag, together with construction and demolition waste fillers, activated by a silicate-based alkaline solution. A novel granulation-based powder-preparation method was introduced to ensure uniform layer spreading and defect-free powder deposition. The printed specimens achieved compressive strengths of approximately 20 MPa and flexural strengths of around 8 MPa, despite containing about 30 vol.% residual porosity. This approach eliminates the need for conventional mechanical mixing in geopolymer production, enables powder reuse, and avoids the requirement for support structures, thereby improving both energy and material efficiency compared with conventional alkali-activated material processing. In addition, the study introduces a new binder jetting route for waste-glass recycling, enabling the production of alkali-activated glass-based components through the jetting of inorganic binders onto glass powders. The results demonstrate the feasibility of transforming glass waste into functional geopolymeric ceramics suitable for large-scale applications. Overall, this work identifies binder jetting of waste-derived ceramics as a promising pathway toward sustainable, scalable, and low-carbon additive manufacturing. Future research will focus on in situ geopolymerization mechanisms, interlayer bonding, and durability optimization to advance this technology toward construction-scale implementation.
CB-3:L32 Development of a Hybrid Biomaterial Polymer-CaCO3 Suitable as a Scaffold in Bone Tissue Regeneration
E. HERNÁNDEZ SÁNCHEZ1, L.A. LINARES-DUARTE1, S. QUIÑONES-ORTIZ1, R. TADEO-ROSAS2, J.G. MIRANDA-HERNÁNDEZ3, N. PÉREZ-HERNÁNDEZ4, A.E. BAÑUELOS-HERNÁNDEZ4, R. CARRERA-ESPINOZA5, 1Instituto Politecnico Nacional, Unidad Profesional Interdisciplinaria de Biotecnología, Departamento de Bioingeniería, La Laguna Ticomán, México City, Mexico; 2Facultad de Ingeniería Mecánica y Eléctrica, Universidad Autónoma de Coahuila, Unidad Torreón, Ciudad Universitaria, Ejido el Águila, Torreón, Coahuila, México; 3Centro Universitario UAEM Valle de México, Laboratorio de Investigación y Desarrollo de Materiales Industriales, Universidad Autónoma del Estado de México, Atizapán de Zaragoza, Mexico; 4Instituto Politecnico Nacional, ENMH, Laboratorio de Microbiologia, La Escalera, México City, México; 5Departamento de Ingeniería Industrial y Mecánica, Universidad de las Américas Puebla, Ex Hacienda Santa Catarina Mártir, San Andrés Cholula, Mexico
This research focuses on developing a hybrid biomaterial that combines the properties of a biopolymer— such as flexibility, low Young's modulus, and low hardness—with those of a bioceramic to meet the demands of bone regeneration. First, polylactic acid particles with a size of 100-200 µm were dissolved in chloroform and mixed with CaCO3 particles at varying percentages. The CaCO3 particles were obtained from eggshells. Specimens of the hybrid biopolymer were formed with a diameter of 12 mm and a thickness of 5 mm under the different experimental conditions. Five mixture conditions were evaluated from 80/20 PLA/CaCO3 to 40/60 PLA/CaCO3 (% wt.). The characteristics of the specimens were assessed by microindentation, nanoindentation, scanning electron microscopy (SEM), optical microscopy (OM), and X-ray diffraction (XRD). Additionally, the density of the hybrid material was evaluated by Archimedes' method. The results showed interesting findings: the hardness and Young's modulus of the material were similar to those of human cortical bone, and the density ranged from 1.1 to 1.56 g/cm3, compared to that of cortical bone (1.9 g/cm3). Finally, the XRD assays indicated the presence of structures composed of C, Ca, H, and O, suggesting that PLA and CaCO3 are interacting.
Session CB-4 Characterization of printed ceramics
CB-4:IL33 X-ray CT Investigation of 3D Printed Ceramics
J. ADRIEN1, H. ELSAYED2, F. GOBBIN2, A. ITALIANO3, E. MAIRE1, P. COLOMBO2,4, M. COFFIGNIEZ1, L. GREMILLARD1, J. LACHAMBRE1, X. BOULNAT1, 1Université de Lyon, INSA de Lyon, CNRS, MATEIS UMR5510, Villeurbanne, France; 2University of Padova, Industrial Engineering Department, Padova, Italy; 3Desamanera Srl, Rovigo, Italy; 4Department of Materials Science and Engineering, Pennsylvania State University, University Park, PA, USA
Additive manufacturing of ceramics enables the production of complex and large-scale components, but also raises important challenges in terms of quality control and understanding of material formation processes. In this context, X-ray computed tomography (X-ray CT) has emerged as a powerful, non-destructive characterization tool that provides multi-scale, 3D insights into the microstructure, geometry, and mechanical behavior of printed parts. This presentation highlights the capabilities of X-ray CT for investigating ceramics produced via additive manufacturing, with a focus on the binder jetting and robotcasting processes. Using representative case studies, we demonstrate how X-ray CT can be used to monitor the different stages of binder jetting, including powder bed characterization, tracking of binder infiltration and reaction, and final part inspection to detect and analyze defects. We also present results obtained from robotcast parts, showcasing the ability of X-ray CT not only to characterize internal microstructures, but also to assess the dimensional accuracy of the printed components. Finally, in situ mechanical tests combined with tomography will be presented, highlighting the potential of this method for studying the mechanical behavior of printed parts.
CB-4:IL34 Nano- and Microscale Characterization of Additively Manufactured Metal-ceramic Nanocomposites
J. SCHWIEDRZIK, Laboratory for High Performance Ceramics, Empa, Switzerland; A. BORZI, A. NEELS, Center for X-ray Analytics, Empa, Switzerland; N. ROHBECK, M. WATROBA, C. GUNDERSON, M. JAIN, J. NIEMELÄ, I. UTKE, J. MICHLER, Laboratory for Mechanics of Materials and Nanostructures, Empa, Switzerland
Architectured materials on the nano- and microscale hold potential for combining usually mutually exclusive properties such as high strength, toughness, and low density. Here, nanostructured composites consisting of a gold matrix and a continuous Al2O3 reinforcement phase were prepared by combining 2 photon lithogra-phy, electrodeposition, and atomic layer deposition. Nanoindentation was performed as well as microcom-pression at temperatures ranging from 23 to 100°C, which showed an improved yield strength, especially at elevated temperatures. Failure mechanisms were identified by SEM imaging and FIB cross sections. The stability of the grain structure was confirmed by in situ X-ray diffraction. Activation volume and energy were determined and hinted at a change in deformation mechanism in at high strain rates. Using finite element simulations of representative unit cells, it was possible to study the stress and plastic strain distribution in the composite and to predict its apparent thermomechanical properties. The study highlights the potential of nanocomposites with improved strength and thermal stability combined with ductility and low density synthesized by microscale additive manufacturing techniques for use in challenging structural applications.
CB-4:L35 Characterization of 3D Printed Ceramics using Dielectric Properties and Small Angle Scattering
R.A. GERHARDT, A. KONGANI, Georgia Tech, Atlanta, GA, USA; J. ILAVSKY, Advanced Photon Source, Argonne National Labs, IL, USA; S. ALLAN, Lithoz Americas LLC, Troy, NY, USA
In this collaborative presentation with Lithoz Americas and the Advanced Photon Source, we will describe the advantages of using a combination of different techniques to characterize the structure and properties of additive manufactured ceramic samples.. We will utilize detailed impedance and dielectric analysis to identify the effect of the orientation of the printed layers, the thickness of the layers as well as the amount of porosity present as a function of the sintering temperature used. We will report on the effects of the relative humidity of the ambient as an additional experimental parameter because it has been shown in numerous previous studies that the conductivity of a porous material can change by as much as five orders of magnitude when in the presence of high humidities [1]. Small angle x-ray scattering is a technique that has been used to characterize the porosity in thermal barrier coatings and other types of porous materials for a number of years and has also shown significant differences with the orientation of the layers. Results will be accompanied by additional microstructural characterization from additional microstructural characterization methods.
[1] W. Cao, R. Gerhardt and J.B. Wachtman, Jr., “Dielectric Relaxation of Water Adsorbed on Monolithic Porous Silica Gels,” Ceram. Trans. vol. 8: 175-184 (1990).
CB-4:L36 Thin Alumina Substrate Fabrication by Lithography based Ceramic Manufacturing Process
P. BHARGAVA, S. NEGI, Metallurgical Engineering & Materials Science, IIT Bombay, Powai, Mumbai, India
The LCM process has been demonstrated for the fabrication of several kinds of geometry such as complex reactors, fine nozzles, filters, modulators, threaded dental implant parts etc. However, no study demonstrates thin parts (< 500 microns) fabrication. The main challenge in fabricating thin parts is to make the part without any warpage in LCM process. This work systematically demonstrates possible reasons for warpage in thin parts as characterized by FTIR, nano-indentation and DTA. Nano-indentation has been utilized to see differences in mechanical properties between the starting layer and the final layer. The creep deformation of the starting and final layers was examined by carrying out nanoindentation in a load control mode and observing the deformation. A commercial slurry Lithalox 500 was used to print alumina substrates using the LCM process. It was observed that warpage in 3D-printed thin parts posed a significant challenge, attributed to the development of a curing gradient resulting from layerwise curing. A post-curing method was proposed and reduction in warpage by 80% was demonstrated. Thus, flat alumina substrates with thickness of ≤ 300 μm were successfully produced through the LCM process.
CB-4:L37 Characterization of the Effects of Thermal Processing Parameters for DLP Additively Manufactured Tri-Calcium Phosphate Ceramics
S.C. CLEMENS, C.W. CHEN, K.P. PLUCKNETT, Department of Mechanical Engineering, Dalhousie University, Halifax, NS, Canada; E. MARIN, Kyoto Institute of Technology, Kyoto, Japan
Tri-calcium phosphate (TCP) ceramic materials are well suited for orthopedic and dental applications due to their biocompatibility and osteoinductive properties. Additive manufacturing processes, such as digital light processing (DLP), are capable of producing individualized geometries with complex structures that further leverage these properties by providing scaffolding for bone growth and integration with the implant. TCP samples were produced by DLP from a commercially available TCP-based slurry. The subsequent thermal processing and resulting material properties were then studied. Thermogravimetric analysis was employed to monitor the debinding process and dilatometry was used to measure both the sintering response of debound parts and the coefficient of thermal expansion in fully processed (i.e., sintered) parts. Differential scanning calorimetry was used to observe the allotropic phase transformation from the β-TCP (rhombohedral) to α-TCP (monoclinic) phase which occurs near 1125 ºC. Samples were produced with sintering temperatures above and below the transus temperature and the effects of the thermal profile on final density, grain size, and mechanical response were examined. Examples of complex-shaped TCP lattice structures will also be presented.
CB-4:L38 Toward Efficient Solvent Debinding Strategies for Alumina and Zirconia Parts Produced via Fused Filament Fabrication
A.P. LUZ, M.H. MOREIRA, M.R. MORELLI, Federal University of Sao Carlos (UFSCar), Department of Materials Engineering (DEMa), Sao Carlos, SP, Brazil; T.W.B. FARIAS, Federal University of Sao Carlos, Graduate Program in Materials Science and Engineering, Sao Carlos, SP, Brazil; P. COLOMBO, University of Padova, Department of Industrial Engineering, Padova, Italy
The feedstocks used for fabricating ceramic parts via fused filament fabrication (FFF) consist of 40–50 vol% ceramic powder homogeneously mixed with multicomponent binders containing thermoplastics, surfactants, and plasticizers. Debinding remains a critical step that strongly affects part integrity and microstructural quality. This study examines the effects of specimen geometry and temperature on the solvent debinding kinetics of alumina and zirconia parts produced from commercial polyolefin-based filaments. Green bodies with different surface area-to-volume (As/V) ratios were immersed in acetone at 30, 40, and 50 °C, and binder removal was quantitatively evaluated over time. Complementary thermogravimetric, porosimetry, and microscopic analyses assessed polymer extraction efficiency and pore development. Binder removal increased with both temperature and As/V ratio, with alumina exhibiting faster dissolution due to higher binder content and distinct polymer chemistry. Activation energies ranged from 10 to 35 kJ·mol⁻¹, decreasing with higher As/V ratios. The zirconia system showed strong agreement (R² > 0.98) with the applied kinetic model, while new empirical polynomial models were proposed to optimize debinding conditions and support efficient post-processing of FFF ceramics.
CB-4:L38b Modifying the Wear Responses of Al2O3 Fabricated using DLP Additive Manufacturing through Processing Control and Microstructure Design
A.M. DAVID, G. BOUBNOVA, S. CLEMENS, K.P. PLUCKNETT, Dalhousie University, Department of Mechanical Engineering, Halifax, NS, Canada
Digital light processing (DLP) has been used for manufacturing alumina (Al2O3) based ceramics to assess and modify their reciprocating wear response. Three aspects of Al2O3 DLP processing/design were investigated: (i) influence of basic DLP process parameters (i.e., layer thickness, build inclination angle, etc.), (ii) effects of micro-patterned Al2O3 surfaces, and (iii) impact of textured Al2O3 microstructures via platelet seeding. Wear rates were measured for samples sliding against b-Si3N4 counter face spheres. Tests were conducted at a frequency of 5 Hz, for up to 60 minutes, with applied normal loads of up to 80 N. This work highlights the how component design and microstructure modification can impact the measured coefficients of friction, specific wear rates, and tribological damage. The work highlights the important surface design and microstructure development criteria that need to be considered when using AM methods for the production of high performance ceramic wear parts.
Session CB-5 Novel applications and validation of AM ceramic components
CB-5:IL39 Direct Ink Writing of Zeolite Pastes for Applications in Atmospheric Water Generation
A. ZOCCA1, X. CHOUQUET1, J. GÜNSTER1,2, 1Bundesanstalt für Materialforschung und -prüfung, Berlin, Germany; 2Institute of Non-Metallic Materials, Clausthal University of Technology, Germany
The scarcity of clean drinkable water is one of the major challenges of our society. Atmospheric water generation (AWG) from the atmospheric humidity is an emerging technology, since water in the atmosphere can be considered as a nearly inexhaustible and available resource. A low-cost and energy efficient solution could be offered by generators based on adsorption and desorption cycles in a sorbent material. In the cycle of a sorption water generator, water is adsorbed from the atmosphere in the sorbent material during the cold cycle period at night time, and it is desorbed and collected by heating the sorbent material during the hot cycle period during the day. Since desorption can be achieved by solar energy during the day, the specific energy consumption of these devices can be very low. The current work is dedicated to the use of zeolite porous bodies produced by additive manufacturing to optimize the efficiency of sorption water generators. Additively manufactured porous structures can offer an optimized compromise between sorbent mass, permeability and sorption kinetics. The presentation will focus on the optimization of the zeolite feedstock and of the processing parameters for the shaping of porous bodies by direct ink writing (DIW) additive manufacturing.
CB-5:IL40 3D Printing Polymer-derived Ceramics to Achieve Efficient Sensors
HUI MEI, Northwestern Polytechnical University, Xi’an City, China
Develop temperature and pressure sensors adapted to extreme environments by studying the 3D-printed polymer-derived ceramics. A temperature-sensitive thin-film sensor was prepared by inkjet printing a mixture of polysilazane/xylene and various fillers including TiB2, ZrB2, and SiC. Meanwhile, high-temperature oxidation of the thin film itself was employed to enhance its stability under high temperatures. Yttria-stabilized zirconia (5% Y2O3) doping was used to achieve solid solution strengthening, while an alumina sol was used as a protective layer to address the poor high-temperature stability of direct-write printed polysilazane/In2O3 temperature-sensitive thin film sensors. The effects of doping with five metal elements Fe, Co, Ti, Al, and Ni on the crystalline transformation, evolution of conductive phases, and piezoresistive sensing performance of SiOC materials were investigated. Additionally, the influence of negative Poisson's ratio structures, characterized by high load-bearing capacity, low thermal expansion, and large deformation, on the piezoresistive properties and sensing mechanisms of the materials was explored, thereby extending the application of metamaterial structures in the field of SiOC sensing.
CB-5:IL41 Catalyst Supports Made by Additive Manufacturing for Bio-sourced Molecules Conversion
Y. LORGOUILLOUX1, M. MOUNAJ1, F. JEAN1, J. DHAINAUT2, C. COURTOIS1, 1Univ. Polytechnique Hauts-de-France, INSA Hauts-de-France, CERAMATHS – Laboratoire de Matériaux Céramiques et de Mathématiques, Valenciennes, France; 2Univ. Lille, CNRS, Centrale Lille, Univ. Artois, UMR 8181 – UCCS – Unité de Catalyse et Chimie du Solide, Lille, France
This study focuses on developing an innovative process to manufacture porous ceramic catalyst supports, based on alumina. By utilizing the stereolithography (SLA) technique, structures with precisely controlled geometries and microstructures can be produced. The first main challenge was to achieve an optimal balance between mechanical strength and textural properties. To this end, and after sintering up to 1600°C, the surface properties of the monoliths have been enhanced using different methods such as chemical etching and/or the coating with an intermediate layer, namely gamma-alumina. These post-treatments allowed increasing the specific surface area of the monoliths from <1 to 20 m²/g. The deposition of a metal-organic framework (MOF), the UiO-66-SO3H has then been studied. This MOF, carrying a sulfonic function (-SO3H), has been successfully used under the powder form for the dehydration of fructose into 5-hydroxymethylfurfural (5-HMF), an essential molecule with broad applications in the food, pharmaceutical, and biofuel industries. It is expected that its deposition onto alumina monoliths will facilitate its recovery. Its long-term catalytic activity and stability will be especially evaluated.
CB-5:L42 3D-printing of LLZTO Ceramic Electrolyte from Aqueous Inks of High Solids Loading
C. RAMÍREZ1, C. MARTÍNEZ-CISNERO2, M. GARCÍA1, C.M. SHI3,4, B. W. SHELDON4, A. VÁREZ2, M. BELMONTE1, 1Instituto de Cerámica y Vidrio, ICV-CSIC, Cantoblanco, Madrid, España; 2Universidad Carlos III de Madrid, Departamento de Ciencia e Ingeniería de Materiales e Ingeniería Química, Leganés, España; 3Department of Mechanical and Aerospace Engineering, Syracuse University, Syracuse, NY, USA; 4School of Engineering, Brown University, Providence, RI, USA
Among the different additive manufacturing methods, direct ink writing (DIW) has emerged as one of those with the greatest advantages for the development of 3D printed battery components, including the possibility of processing a wide variety of materials, easy customization, high resolution, design versatility, and low cost. Various ceramics and ceramic composites have been successfully printed using this method, and in recent years, research efforts have also been focused on the 3D printing of solid electrolytes. Of all the ceramic electrolyte families, the garnet type based on doped Li7La3Zr2O12 (Al-, Ta-, Ga-...LLZO) is being developed as an alternative with excellent mechanical properties, ambient stability, and good stability against the Li anode. In this work, we have prepared Ta-doped LLZO raw powders by solid-state reaction and developed aqueous inks with a powder content of up to 73 wt.% for extrusion by DIW. 3D-printed structures with lattice and bulk designs were successfully sintered, achieving densities exceeding 87% of theoretical density. Their microstructure, mechanical properties, and ionic conductivity were investigated.
CB-5:L43 Design and Characterization of TPMS Calcium-Phosphate Scaffolds for Bone Regeneration
G. VERLATO, E. BERNARDO, H. ELSAYED, Department of Industrial Engineering, University of Padova, Padova, Italy
Large bone defects resulting from trauma or disease remain a major clinical challenge, particularly with the aging population. This work presents the design and characterization of additively manufactured calcium phosphate scaffolds that combine controlled architecture with bioactive composition. Photocurable inks based on β-tricalcium phosphate and hydroxyapatite were formulated and systematically characterized in terms of rheology, light-curing kinetics, and thermal behavior to ensure printability and defect-free sintering. Masked stereolithography was employed to fabricate triply periodic minimal surface (TPMS) scaffolds, whose geometry provides an optimal balance between mechanical strength and permeability. The fabricated scaffolds were evaluated for morphological fidelity and mechanical performance, assessing the influence of design, printing, and thermal processing parameters on the final structural quality. Preliminary biological assays indicated good cytocompatibility, supporting the suitability of the scaffolds for further biological evaluation. Overall, this study contributes to the development of reproducible and functionally optimized ceramic scaffolds for bone regeneration.
CB-5:IL44 Decarbonizing Technical Ceramics through Additive Manufacturing Approaches
N. KATSIKIS, Kyocera Fineceramics Europe GmbH, Germany
The pathway toward climate neutrality in ceramics demands more than incremental improvements. It requires a rethinking of how we design, produce, and use technical ceramics. With its inherently high energy demand, the ceramic industry must identify leverage points across the entire value chain. This presentation explores how additive manufacturing (AM) can transform that pathway. Rather than simply substituting production methods, AM enables new paradigms in efficiency, material utilization, and product functionality. It challenges long-standing process constraints and offers entirely new design freedoms that align directly with decarbonization goals. Using selected industrial cases, the talk will illustrate how innovative ceramic AM concepts can cut emissions, simplify production chains, and unlock design spaces. The presentation will conclude by outlining a holistic decarbonization framework that connects digital process control, circular material use, and matching ceramic applications, thus, offering a glimpse of what a climate-neutral ceramics industry could look like.
CB-5:IL45 Yttria-based Transparent Ceramic Fabrication using Photopolymerization-based Additive Manufacturing
HUI-SUK YUN, Korea Institute of Materials Science (KIMS), Changwon, Korea
A variety of shaping methods, such as dry pressing, gel casting, and slip casting, can be used to create high-quality translucent Yttria (Y₂O₃). However, the use and application of transparent Y₂O₃ would be impeded by the geometric control constraints of shaping operations. Here, we suggest additive manufacturing (AM) based on digital light processing (DLP) as one of the best ways to address this structural flaw. The key elements controlling the transparency were identified in this study, which used DLP-based AM technology with vacuum sintering assistance to create a 3D-structured transparent YO₃ ceramic. To control grain growth, we added zirconia and lanthana to the sintering process. To regulate printing accuracy, printing parameters such as UV light intensity and layer thickness were tuned. The clear Y₂O₃ ceramics achieved a fine-grained, dense microstructure after pre-sintering in air and vacuum sintering procedures, resulting in a high transmittance that reached 98.7% of the theoretical limit. The 3D Y₂O₃ lens, which has been polished using recently created 3D polishing technology, has exceptional optical imaging capabilities. This study shows that ceramic AM's ability to overcome Y₂O₃'s geometric control constraint holds great promise for increasing the material's use.
Session CB-6 Design for AM
CB-6:IL46 Escaping Flatland: How 3D Printing Can Change Advanced Ceramic Materials Properties and Applications
V. ESPOSITO, Department of Energy Conversion and Storage, Technical University of Denmark, Kgs. Lyngby, Denmark
Additive manufacturing is revolutionizing the field of advanced ceramics, providing unprecedented control over material architecture and functionality. In this presentation, we explore how three-dimensional (3D) printing, particularly high-resolution techniques such as digital light processing, enables the design of ceramic materials beyond traditional planar constraints. By leveraging architected geometries, it becomes possible to decouple density, mechanical strength, and transport properties, unlocking novel electrochemical and electromechanical performance. We discuss recent breakthroughs in functional ceramic metamaterials, including energy storage devices, electromechanical transducers, and ionically active scaffolds, where 3D structuring plays a central role in enhancing performance. Through experimental results, numerical simulation, and application-oriented case studies, the talk highlights how 3D printing is not just a fabrication tool but a platform for material innovation.
CB-6:IL47 Numerical Design of SiC-based Open-cell Foams Through Topological Optimisation for Use as Volumetric Solar Absorbers
A. DE LA VAUVRE, Y. FAVENNEC, B. ROUSSEAU, LTEN, Nantes Universite, CNRS, Nantes Cedex, France; L. CANGEMI, IFP Energies Nouvelles, Rueil-Malmaison, France
Open Volumetric Solar Reveivers are convective-conductive-radiative heat exchangers which allows to convert concentrated solar radiation (1-5 MW/????2) into high-temperature heat. These exchangers can be engineered using SiC-based porous media based in reason of their good thermal, radiative and mechanical properties. Their numerical design is a key step in guaranteeing a homogenous spatial distribution of the internal temperature, even though they are heated from only one side with an inhomogeneous solar beam, which is a source of strong spatial thermal gradients. Such heterogenous heating can lead to prejudicial thermal stresses. To cope with this issue, a continuous direct 1D modelling of the conjugated heat transport is proposed with a view to apply a topological optimisation loop. In this process, we will focus on the influence of the choice of the extinction coefficient on the rendering of the porosity profile resulting from the topology optimisation according to a given objective function (minimising thermal gradient, maximizing solar-to-heat conversion). The results will be presented and discussed when dealing with potential additive manufacturing processes.