© 2015 HRL
Laboratories. Photo by Dan Little Photography.
(January 1, 2016) Researchers
at HRL Laboratories, LLC, have achieved a new milestone in 3D printing
technology by developing a process that overcomes the limits of traditional
ceramic parts and enables the development of high temperature, high strength
ceramic components. According to HRL Sensors and Materials Laboratory Senior
Scientist Dr. Tobias Schaedler, "Our team surmounted the challenges
inherent in ceramics to develop an innovative material that has myriad
applications in a variety of industries."
Schaedler credited HRL’s Senior Chemical Engineer Zak Eckel
and Senior Chemist Dr. Chaoyin Zhou with inventing a resin formulation that can
be 3D printed into parts of virtually any shape and size. The printed resin can
then be fired, converting it into a high strength, fully dense ceramic.
"The resulting material can withstand ultrahigh temperatures in excess of
1700°C and exhibits strength ten times higher than similar materials,"
said Schaedler.
This innovative process enables additive manufacturing of
complex shaped ceramic parts. "Ceramics are much more difficult to process
than polymers or metals because they cannot be cast or machined easily,"
said Schaedler. Traditionally, ceramic parts are consolidated from powders by
sintering, which introduces porosity and limits both achievable shapes and
final strength. "With our new 3D printing process, we can take full
advantage of the many desirable properties of this silicon oxycarbide ceramic,
including high hardness, strength and temperature capability, as well as
resistance to abrasion and corrosion," said Schaedler.
According to Schaedler, the novel process and material have
the potential to be used in a wide range of applications. "Everything from
large components in jet engines and hypersonic vehicles to intricate parts in
microelectromechanical systems and electronic device packaging could be
fabricated," he said.