Abstract
Herein, a novel method for hierarchically porous mullite ceramics with complex and fine structure was proposed, that is vat photopolymerization of multi-phase Pickering emulsion. Pickering emulsions stabilized by mixed particles features water in oil type, high solid content, suitable rheological properties and excellent ultraviolet-curing ability, making them appropriate pastes for vat photopolymerization. The printed components possess hierarchically porous structure involving interconnected mm-scale pores designed by three-dimensional model, uniform μm-scale pores derived from emulsion droplets and less voids generated by the removal of photosensitive resin in the location of continuous phase. Therefore, porous mullite ceramics with octet lattice structure possess excellent compressive strength up to 4.3 MPa at high porosity of 74.08% compared to the counterparts from pure resin-based suspension. The products from this facile, universal and effective method could serve as ideal candidates for catalytic filters, biological scaffolds and electronic components owing to their designable structure and outstanding multifunctionality.
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