Abstract
Additive manufacturing of Polymer-Derived Ceramics (PDCs) is regarded as a disruptive fabrication process that includes several technologies such as light curing and ink writing. However, 3D printing based on material extrusion is still not fully explored. Here, an indirect 3D printing approach combining Fused Deposition Modeling (FDM) and replica process is demonstrated as a simple and low-cost approach to deliver complex near-net-shaped cellular Si-based non-oxide ceramic architectures while preserving the structure. 3D-Printed honeycomb polylactic acid (PLA) lattices were dip-coated with two preceramic polymers (polyvinylsilazane and allylhydridopolycarbosilane) and then converted by pyrolysis respectively into SiCN and SiC ceramics. All the steps of the process (printing resolution and surface finishing, cross-linking, dip-coating, drying and pyrolysis) were optimized and controlled. Despite some internal and surface defects observed by topography, 3D-printed materials exhibited a retention of the highly porous honeycomb shape after pyrolysis. Weight loss, volume shrinkage, roughness and microstructural evolution with high annealing temperatures are discussed. Our results show that the sacrificial mold-assisted 3D printing is a suitable rapid approach for producing customizable lightweight highly stable Si-based 3D non-oxide ceramics.
Highlights
Ceramic materials, due to their superior properties such as high hardness, high melting point, low density and environmental tolerance, play an important role in the development of cutting-edge technologies
Advanced 3D non-oxide ceramics with complex architectures are currently regarded for various applications requiring stability under severe conditions
Preceramic polymers are suitable for 3D printing as they can be adapted to different additive manufacturing (AM) technologies
Summary
Due to their superior properties such as high hardness, high melting point, low density and environmental tolerance, play an important role in the development of cutting-edge technologies. We are interested in non-oxide silicon-based Polymer-Derived ceramics (PDCs) known for having great thermochemical stability, high mechanical properties, oxidation resistance, chemical resistance, high melting point, wear resistance and high hardness compared to their oxide homologues [13,16,25,26,27,28]. They are explored as a versatile class of materials for various applications in catalysis, energy, machinery and biomedical engineering [8]. Low-cost and available thermoplastic polymers as the preform’s material and reducing the quantity of preceramic polymers for coating without the use of catalysts reduce the overall manufacturing process
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