Ceramic Manufacturing Research Articles

(Invited) Wide Bandgap Semiconductor Based Devices for Digital and Industrial Applications

Wide bandgap (WBG) semiconductor devices based on SiC, GaN and Ga2O3 provide advantages for many strategic initiatives in various industrial sectors, such as data centers, electric vehicles, renewable energy systems like solar and wind power inverters. Innovations in WBG technologies would enable new paths on energy efficiency for pushing towards sustainable perspectives. For instance, higher efficiency and lower power dissipation are always desirable for digital economy/society and power electronic applications owing to the energy saving at the end with the goal to reduce CO2 emissions.Here we will emphasize our ongoing WBG semiconductor related research/development and innovation activities, especially on GaN technology owing its rapid/huge demanding in the market nowadays. Thus, the GaN material growth, device processing/packaging and characterization/verification will be elaborated in detail in this talk.In recent years an epitaxy technique to grow large diameter GaN-on-Si wafers by coalesced nanowire has been established at RISE ProNano Lab. The GaN nanowires are epitaxially grown and then merged into a planar epitaxial film with reduced dislocation density as compared to commercially available substrates. It allows for fabrication of thick GaN layers that required for high-voltage vertical devices on Si. A 4.1-µm-thick GaN device layer on a GaN-on-Si template has been grown successfully. It has a threading dislocation density on the order 108 cm-2 and a root mean square roughness of < 0.4 nm. This result has laid the foundation for scaling to the thicker (10-12 µm) crack-free GaN drift layer on lager wafer diameters up to 200 mm.RISE has long term experience working on GaN based High Electron Mobility Transistors (HEMTs). Since 2019 we have worked on high performance and cost-competitive power HEMTs on buffer-free GaN-on-SiC wafers in frame of EU UltimateGaN project. It has focused not only on verification of the high device performance but also on its yield for revealing its competitiveness in the cost-sensitive power electronics market. The fabricated HEMTs demonstrated the expected threshold voltage, good linearity with gate length and width, Ion/Ioff ratio of 1010 as well as high output current up to 16 A with multiple fingers. In such wafer level device fabrication, different types of multi-finger HEMTs could be included with designed electrodes for flip-chip soldering them into package modules. The power module was designed and produced in house by ceramic additive manufacturing (AM), also known as three-dimensional (3D) printing. The package design has aimed to address the stringent thermal and electrical requirements of these types of HEMTs for power electronic applications. Importantly the ceramic AM package design also enables the incorporation of intricate 3D features into the package structure for achieving increased electrical isolation distance between the source and drain contact pads of the HEMT in the package.In addition, SiC and Ga2O3 based sensors/devices will be briefed in this talk, which will provide a glance for design and fabrication of the hybrid WBG components for various greener applications.

Effect of process parameters on characteristics and pore structure of foam ceramics prepared from granite sawing dust

Foam ceramics made from solid waste have recently attracted considerable interest because of their environmentally friendly and sustainable properties. This study examines the manufacturing of foam ceramics through the direct sintering of granite sawing dust. An orthogonal experimental design was employed to explore the impact of the foaming-agent content, sintering temperature, holding time, and moulding pressure on the characteristics of foam ceramics. The experimental and analytical results show that under the given conditions involving a foaming agent content of 0.8 wt%, a sintering temperature of 1200 °C, a holding time of 30 min and a moulding pressure of 5 MPa, the produced foam ceramics have excellent properties. These included a bulk density of 0.892 g/cm³, water absorption of 0.130 %, porosity of 59.67 %, high compressive strength of 10.721 MPa, and thermal conductivity of 0.247 W/(m·K). Analysis of the pore structure revealed that the samples had an evenly distributed and sealed pore structure, which effectively increased the porosity and bulk density. This study effectively demonstrates the viability of producing porous ceramics from granite sawing dust, presenting a green and economically sustainable method for waste management and the creation of high-functioning materials. These findings offer promising prospects for the greater implementation of granite waste in the construction sector.

Thermodynamic analysis of the reactions of strontium anorthite formation during the firing of thermal shock resistance ceramics based on the eutectic glasses of the SrO–Al2O3–SiO2 systems

Thermal shock resistance ceramic materials must have a high degree of sintering to ensure the required mechanical strength, erosion resistance, and resistance to high-temperature oxidation. However, the search for effective ways to achieve a high degree of sintering of ceramic materials based on the SrO–Al2O3–SiO2 system at low temperatures requires a large amount of experimental research. The aim of this work is to analyze thermodynamically the reactions of strontium-anorthite phase formation at the points of triple eutectics of the SrO–Al2O3–SiO2 system under low-temperature firing conditions. The eutectic points were selected in the region of strontium anorthite crystallization and had a temperature not exceeding 14000C. It has been established that in the case of compliance with the stoichiometric ratio, the final product of the interaction of the components of eutectic glasses S-1 and S-2 with the charging components is the strontium anorthite phase. The most probable is the formation of strontium anorthite in the interaction of eutectic glass components with Al2O32SiO2, which is a product of kaolinite dehydration (Al2O32SiO22H2O). It has been found that the compounds SrOSiO2 and 2SrOAl2O3SiO2 are most active in the interaction with the charging components in the direction of formation of the strontium anorthite phase than SiO2 tridymite. As a result, the sintering of strontium-anorthite compositions at a temperature of 9000C causes a significant increase in the content of the crystalline phase of strontium anorthite. The determined patterns allow making a reasonable choice of glass in the SrO–Al2O3–SiO2 system for the further manufacture of low-temperature strontium-anorthite ceramics.

Additive manufacturing of ceramics: Advances, challenges, and outlook

Additive manufacturing of ceramics: Advances, challenges, and outlook

Status of 3D Printing Technology for Preparing Bioceramic Materials

3D printing technology has great advantages in small batch and personalized customization, so it has attracted much attention in the biomedical field. The consumables available for 3D printing include polymer, metal, ceramic and derived materials. Biomedical ceramics, with high melting point and poor toughness, are the most difficult materials to be used in 3D printing. The progress of 3D printing ceramic preparation process using ceramic powder, ceramic slurry, ceramic wire, ceramic film and other different raw materials as consumables are reviewed, and the surface roughness, size, density and other parameters of ceramics prepared by SLS, 3DP, DIW, IJP, SL, DLP, FDM, LOM and other different processes are compared. The study also summarizes the clinical application status of 3D printed bioceramics in the field of hard tissue repair such as bone tissue engineering scaffolds and dental prostheses. The SL ceramic additive manufacturing technology based on the principle of UV polymerization has better manufacturing precision, forming quality and the ability to prepare large-size parts, and can also endow bioceramics with better biological properties, mechanical properties, antibacterial, tumor treatment and other functions by doping trace nutrients and surface functional modification. Compared with the traditional subtractive manufacturing process, the bioceramics prepared by 3D printing not only have good mechanical properties, but also often have better biocompatibility and osteoconductivity.

The environmental sustainability assessment of building ceramic manufacturing based on the LCA-emergy approach

The environmental sustainability assessment of building ceramic manufacturing based on the LCA-emergy approach

Carbon emissions marginal abatement cost and its influencing factors from the construction and hygienic ceramics manufacturing industries in China

Reducing China's carbon dioxide (CO2) emissions primarily involves efforts from energy-intensive sectors, including the construction and hygienic ceramics manufacturing industries. Although the majority of extant studies have focused on estimating marginal abatement cost (MAC) of CO2 emissions, there are mainly four shortcomings: (i) most of studies have explored this issue at industrial level or provincial level, the evidence at the enterprise level is limited; ii) the selection of emissions abatement measures and strategies is normally arbitrary; iii) the characteristics of MAC changing with the amount of emissions reduction is usually ignored; and iv) the analysis of influencing factors for MACs is not included. Here, this study provided an innovative MAC estimation for China's 913 construction ceramics enterprises and 360 hygienic ceramic enterprises. A quadratic directional distance function method, including multiple emissions abatement measures and all possible directional vectors representing different emission reduction strategies, is applied to calculate the lowest MAC. We further incorporate the abatement level from 1 to 99% into MACs estimation, and investigated its influencing factors. The results mainly illustrated three relevant findings. (i) The average MAC for construction ceramics manufacturing is 2203 CNY/t CO2, which is lower than that for hygienic ceramics manufacturing of about 8416 CNY/t CO2. (ii) Construction ceramics production enterprises would be willing to downscale production to achieve the lowest cost for emissions reduction, whereas hygienic ceramics production enterprises tend to choose increasing the intermediate input. (iii) Energy use efficiency positively influences MACs for both construction and hygienic ceramics production enterprises, while intermediate input rate, energy consumption structure (the proportion of fuel coal consumption in total energy) and profitability are negatively related to MAC. Results and findings can provide references for the formulation of carbon emission reduction policies in China's construction and hygienic ceramics manufacturing industries.

Comparison between Lithium Substitution and Doping on the Physical and Piezoelectric Properties of Lead-Free BCZT Ceramics

Defects generation in ceramics by element substitution or doping may improve their properties. However, different results will be obtained even though the same element is involved due to different mechanisms. Ceramics Ba0.85Ca0.15Ti0.9Zr0.1O3 (BCZT) is one of the potential candidates to replace lead-based material PZT. However, the conventional method requires high-temperature calcination and sintering process to synthesize this material. Thus, Lithium (Li) can act as the sintering aid to lower the temperature at the same time, the properties of piezoelectric can be enhanced. In this paper, the structural, physical, and piezoelectric performance of lead-free Ba0.85Ca0.15Ti0.9Zr0.1O3 (BCZT) ceramics with Lithium Li substitution and doping, synthesized by the solid-state reaction method were studied. The substitution of Li increases the density, ρ and piezoelectric coefficient, d33 of BCZT which are 4.075 g/cm3 and 304.6 pC/N, respectively. These results demonstrate that Li substitution is more beneficial to the piezoelectric properties than doping because it produces higher grain boundary resistance and activation energy and has lower conductivity than doping. This can provide a definite strategy during the chemical composition design and manufacture of BCZT ceramics.

Fourth and fifth seasons of the Nubian Archaeological and Anthropological Expedition of the Anuchin Research Institute and Museum of Anthropology, Lomonosov Moscow State University at the Sites of Deraheib and Onib (the Republic of Sudan). Part I. Survey

Introduction. The Nubian expedition of the Lomonosov MSU carried out survey in the Onib Depression in December 2022. The survey revealed several surface scatters and two stone age sites Onib-1 and Onib-Outcrop. Materials and methods. The materials for the article were artifacts (stone tools and debitage, fragments of ceramics) discovered at the surface scatters and sites as well as samples for OSL dating, loss-on-ignition and pollen analysis taken from sites. For comparison, we used stone tools discovered by the Nubian expedition of the USSR Academy of Sciences in 1961-1963. The artifacts found at the sites were documented (marked on a map, photographed and described). Several samples for OSL dating were taken at both sites. Sample preparation and gamma spectrometry, as well as OSL measurements, were conducted by standard methods. Analysis of the decoration of ceramic fragments found at the Onib-1 site was carried out. Also, based on the prepared thin sections, a technological and petroglyphic analyses of the obtained fragments were carried out. Samples were taken from different layers of the sites Onib-1 and Onib-Outcrop to determine the content of organic residues and spore-pollen analysis. Sample preparation and analysis were carried out following the standard procedures. Results and Discussion. Analysis of the finds made at the sites indicates that the entire Wadi al-Allaqi region from the Red Sea Mountains to the Nile Valley was inhabited during the Neolithic period. OSL dating for Onib-1 and Onib-Outcrop sites indicates that the sedimentary deposits were formed during the Neolithic Subpluvial. These data are also confirmed by the results of ceramic analysis. The layers in which the ceramic fragments were found can be dated back to the 3rd millennium BC. Petrographic analysis of thin sections of ceramics from Onib-1 site indicates the use of local material for the manufacturing of ceramics. The results of loss on ignition analysis did not reveal a sufficient content of organic residues for a comprehensive paleoecological study that overall indicates unfavorable conditions for the accumulation of organic matter in the studied deposits. Conclusion. The results obtained indicate high prospects of continuing field research in the Onib Depression aimed at discovering and excavating Neolithic sites. @ 2023. This work is licensed under a CC BY 4.0 license

3D printing of ultra-thin veneers made of lithium disilicate using the LCM method in a digital workflow: A feasibility study.

This article highlights the feasibility of the additive fabrication of ultra-thin veneers made of lithium disilicate using the lithography-based ceramic manufacturing (LCM) method. An esthetical appealing restoration of anterior teeth with thin ceramic veneers is considered one of the ultimate challenges in restorative dental prosthetics. These sophisticated restorations can be fabricated in different ways. Both analog and digital subtractive manufacturing processes have been used to date. Either of the methods is highly demanding for the dental technician and dental engineering due to the required low ceramic layer thickness. Modern additive manufacturing methods, for example LCM technology, enable the production of ultra-thin lithium disilicate veneers with layer thicknesses of down to 0.2 mm and could therefore represent a viable alternative for this indication in the future. Digital technologies can help streamline workflows, make the outcome more predictable and reproducible, and even further optimize therapeutic restorative options such as highly esthetic veneers for anterior teeth. The reduced material thickness allows for a true non-prep solution or minimally invasive preparation.

Preceramic Polymers for Additive Manufacturing of Silicate Ceramics.

The utilization of preceramic polymers (PCPs) to produce both oxide and non-oxide ceramics has caught significant interest, owing to their exceptional characteristics. Diverse types of polymer-derived ceramics (PDCs) synthesized by using various PCPs have demonstrated remarkable characteristics such as exceptional thermal stability, resistance to corrosion and oxidation at elevated temperatures, biocompatibility, and notable dielectric properties, among others. The application of additive manufacturing techniques to produce PDCs opens up new opportunities for manufacturing complex and unconventional ceramic structures with complex designs that might be challenging or impossible to achieve using traditional manufacturing methods. This is particularly advantageous in industries like aerospace, automotive, and electronics. In this review, various categories of preceramic polymers employed in the synthesis of polymer-derived ceramics are discussed, with a particular focus on the utilization of polysiloxane and polysilsesquioxanes to generate silicate ceramics. Further, diverse additive manufacturing techniques adopted for the fabrication of polymer-derived silicate ceramics are described.

Enhancing rheology and physico-mechanical properties of ceramic slurries: Effect of the addition of various types of deflocculants

This study investigated the impact of various types of deflocculants with different chemical composition on ceramic slurries rheology. Organic and inorganic plasticizers were substituted for sodium silicate plasticizers in floor tile recipes, and their effects on rheology were assessed. The interactions of these materials with the silicate and ceramic slurry in terms of synergistic, antagonistic, and additive properties were then determined. In addition, the physico-mechanical properties of the ceramic bodies obtained using commercial plasticizers were investigated. Microstructural analysis using scanning electron microscopy (SEM) and mineralogical properties using x-ray diffraction (XRD) were performed. Results revealed that the addition of silicate to the slurry had a synergistic effect on rheology, reducing second viscosity to 50 s with a thixotropy ratio of 22%. Moreover, the flexural strength of the sample with 1% silicate addition increased by 13.6%, indicating positive effects on physico-mechanical properties. SEM analysis indicated the formation of a more uniform dispersion of particles with silicate addition. These findings suggest that incorporating silicate into ceramic slurries can effectively enhance both rheology and physico-mechanical properties, holding significant implications for ceramic tile and product manufacturing.

Optimization, formation, and evolution of the photoinduced curing gradients and in-situ lamellar gaps in additive manufacturing of ZrO2 ceramics: From curing to sintering behaviors

The photoinduced curing gradients and in-situ lamellar gaps were related to the three-dimensional curing mechanism of stereolithography and researched in this work. Based on the photocuring mathematic theories presented by our team, photoinduced curing gradients were influenced by printing parameters such as laser power and frequency, scanning angle, and printing thickness. Among these curing gradients, the inadequate curing area was the main factor affecting the surface quality and physical properties of ceramics. The in-situ lamellar gaps were derived from the inadequate curing area. The lamellar gap size of green bodies was enlarged in brown bodies (sintering at 1170 ℃) and shrunk in sintered bodies (sintering at 1500 ℃). The correlations between the surface quality and printing parameters were clarified by establishing mathematical formulations of the lamellar gap size. Furthermore, anisotropic volume shrinkage, anisotropic surface topography, and density and hardness evolutions were associated with the wrapped particle density differences induced by the photoinduced curing gradients. Finally, the optimal printing parameters (75% of laser power, laser frequency of 150 kHz, scanning angle of 90º, printing thickness of 25 μm, and scanning speed of 2.5 m/s) were obtained by the orthogonal experimental analysis. This study provides a distinct understanding of the high-quality forming and extreme-performance manufacturing of stereolithography.

Binder-free additive manufacturing of ceramics using hydrothermal-assisted jet fusion

Ceramic additive manufacturing (AM) typically uses a high fraction of organic binders to form pre-sintered green parts that require a post de-binding process to remove. The de-binding process inevitably results in severe gas expansion and residual chars, leading to structural defects, accumulated stress, and compromised material properties in the final parts. Here we report a binder-free additive manufacturing process named hydrothermal-assisted jet fusion (HJF) that utilizes a hydrothermal method to create geometrically and compositionally complex ceramics under mild temperatures. The HJF process employs a selectively deposited volatile dissolving ink, high pressure, and milt heat to strategically fuse a ceramic powder bed into complex geometries. Compared to traditional AM methods for ceramics, the HJF process eliminates the need for organic binders in green part fabrication and offers the potential to directly co-print ceramics with other dissimilar materials, such as polymers and metals, enabling the development of novel multi-functional ceramic composites.

Differentiation of Late Bronze Age Nubian- and Egyptian-style ceramics from northern Sudan by manufacturing firing temperatures using Raman spectroscopy

Ceramic samples of Nubian and Egyptian traditions dating to the 18th Dynasty of the New Kingdom period (1550–1290 BCE) from the ancient temple towns of Sai Island and Dukki Gel were analyzed using optical light microscopy and micro-Raman spectroscopy to identify the relative maximum firing temperatures reached during their manufacturing process. Our data demonstrate that Egyptian-style ceramics experienced slightly higher maximum firing temperatures than Nubian-style ceramics based on measurements of carbonized plant residues and sub-µm-scale carbon within the matrices, which were likely added as ash to temper the clay. Although no absolute values can be given for the different traditions, maximum firing temperatures likely ranged from 700 °C to 800 °C. Alteration due to oxidative weathering over time after the deposition of the ceramics affected all samples, although more so the specimens from Dukki Gel than from Sai Island. Raman spectroscopy gives new insights to characterize firing conditions during Nubian and Egyptian ceramics manufacture, especially when using a 532 nm measuring laser wavelength on sub-µm-scale carbon within the matrix.

Reusing Ceramic Waste as a Fine Aggregate and Supplemental Cementitious Material in the Manufacture of Sustainable Concrete

A viable strategy for promoting sustainable development and a cleaner environment is the reuse of demolition-related ceramic waste and ceramic manufacturing byproducts in the production of concrete. The purpose of this study is to assess the possibilities for using ceramic waste in the production of concrete as a fine aggregate and cementitious material. The effectiveness of concrete mixtures incorporating 20–100% ceramic waste fine (CWF) as a replacement for natural fine aggregate and 10–30% ceramic waste powder (CWP) in place of cement was evaluated. Their influence was assessed with respect to workability, mechanical performance, durability, and elevated temperature resistance. The results were analyzed via energy dispersive x-ray (EDX) and scanning electron microscopy (SEM). The findings illustrated that the increase in the replacement levels of CWP and CWF decreases the concrete workability. The mechanical performance of concrete mixtures is enhanced under compression and flexural tests as the replacement ratios of CWF and CWP increase up to 50% and 10% as replacements of sand and cement, respectively. The increases in compressive and flexural strength were 5.33% and 8.14%, respectively, at age 28 days. The concrete water permeability significantly increases as the CWF replacement ratio increases, and the incorporation of CWP reduces this negative impact. After exposure to 200, 400, 600, and 800 °C, the residual compressive strengths of concrete mixtures incorporating CWF and CWP were up to 95.02%, 89.66%, 74.33%, and 51.34%, respectively, compared to control mixtures, which achieved 84.25%, 76.03%, 59.36%, and 35.84% of their initial strength. Microstructure analysis revealed that combining CWP and CWF significantly improves cement hydration when compared to the reference mixture. Thus, the use of CWF and CWP in the production of masonry mortar might be an economical alternative that would aid in raising the recycling rate of demolition and construction debris and supporting sustainable growth in the building sector.

Computer-Aided Visual Inspection of Glass-Coated Tableware Ceramics for Multi-Class Defect Detection

Quality control procedures in the manufacturing of tableware ceramics require a demanding, monotonous, subjective, and faulty human manual inspection. This paper presents two machine learning strategies and the results of a semi-automated visual inspection of ceramics tableware applied to a private dataset acquired during the VAICeramics project. In one method, an anomaly detection step was integrated to pre-select possible defective patches before passing through an object detector and defects classifier. In the alternative one, all patches are directly provided to the object detector and then go through the classification phase. Contrary to expectations, the inclusion of the anomaly detector demonstrated a slight reduction in the performance of the pipeline, which may result from error propagation. Regarding the proposed methodology for defect detection, it exhibits average performance in monochromatic images with more than 600 real defects in total, efficiently identifying the most common defect classes in highly reflective surfaces. However, when applied to newly acquired images, the pipeline encounters challenges revealing a lack of generalization ability and experiencing limitations in detecting specific defect classes, due to their appearance and limited available samples used for training. Only two defect types presented high classification performance, namely Dots and Cracked defects.

Ceramic and Metal Additive Manufacturing of Monolithic Rotors From SiAlON and Inconel and Comparison of Aerodynamic Performance for 300W Scale Microturbines

Abstract The gas turbine industry is continuously developing and testing new materials and manufacturing methods to improve the performance and durability of hot section components, which are subjected to extreme conditions. SiAlON and Inconel 718 are especially desirable for turbomachinery applications due to their high strength and high-temperature capabilities. To demonstrate the viability of additive manufacturing for small-scale turbomachinery for 300W scale microturbines, a monolithic rotor with a design speed of 450,000 RPM containing radial turbine and compressor was developed considering additive manufacturing constraints. The geometry was manufactured from SiAlON and Inconel 718 using lithographic ceramic manufacturing and selective laser melting, respectively. The additive manufacturing and thermal process parameters as well as material characterization are described in detail. Surface and computerized tomography scans were conducted for both rotors. While the metallic rotor showed undesirable printing artifacts and a large number of defects, the ceramic part achieved a level of relative precision and surface quality similar to large-scale production via casting. To compare turbomachinery performance, an aerodynamic test facility was developed allowing to measure pressure ratios and efficiency of small compressors. The rotors were tested in engine-realistic speeds, achieving a compressor rotor pressure ratio of 2.2. The ceramic part showed superior efficiency and pressure ratio compared to the Inconel rotor. This can be explained by lower profile and incidence losses due to a higher fidelity physical representation of the model geometry and better surface finish.

Machine learning-based design for additive manufacturing in biomedical engineering

While ceramic additive manufacturing (AM) technologies have shown great promise to create functional scaffolds with tailored biomechanical properties, the true potential of these advanced techniques has not been fully exploited yet due to lack of practical design optimisation approaches. To address this challenge, a machine learning (ML)-based design approach is proposed herein where ceramic 3D printing techniques are combined to fabricate functionally graded tissue scaffolds composed of Triply Periodic Minimal Surfaces (TPMS), aiming to fulfil the anticipated biomechanical requirements for the target bone regeneration outcomes. The proposed ML based design strategy couples a Bayesian optimisation (BO) algorithm to enable time-dependent mechano-biological optimisation of the 3D printed ceramic scaffolds at a reasonably low computational cost. For a representative example relating to bone scaffolding in a segmental defect of sheep tibia, the simulated results demonstrate that the optimised functionally graded scaffolds significantly enhance bone ingrowth outcomes. Furthermore, a Lithography-based Ceramic Manufacturing (LCM) technique is employed to fabricate the optimised scaffolds based on the proposed ML-based design framework, followed by micro-CT analyses of the additively manufactured ceramic scaffolds to assess their geometric qualities. This study is expected to gain new insights into mechanical sciences on design for varying material conditions and provide an effective design tool for ceramic additive manufacturing.

Reducing High Temperature System Development Cycle Time and Cost with Additively Manufactured Connectors

Connectors are a fundamental part of Ozark IC’s high temperature modules from characterization and test packages to Ozark IC’s XNode® data acquisition and single-board computing modules. Development of rugged high temperature electronic systems requires the co-development of similarly rugged high temperature connectors. The design and development of connector solutions enable test and evaluation of high temperature systems which would otherwise require fulfillment of a commercial connector order. There is a nascent supply chain of rugged, high temperature-rated connector designs but manufacturer lead times for such commercial products can exceed an entire design, prototype, and test cycle. Such delays are incompatible with rapid design iterations and fail-fast strategies employed in the development of extreme environment electronics – especially when the design and test cycles can change the requirements or specifications of the connectors. Polymer and ceramic additive manufacturing techniques enable in-house connector fabrication and support a connector co-development cycle that complements the pace and interdependent requirements of high temperature system development. These solutions are simple and reliable under laboratory conditions, operating for thousands of hours at 200 °C [1] and hundreds of hours at 800 °C [2]. The use of proprietary connectors manufactured with additive techniques and digital tooling lends an extra degree of freedom to system design and enables the trade-off of connector with system design specifications that greatly accelerates system ruggedization. Electrical connectors represent the final interface between an electronics module and the outside world. A failure of a connector is a failure of packaging that makes the module opaque to the tester and renders the power and robustness of any electronic system moot.