Digital Light Processing 3D Printing Research Articles

Digital light processing based multimaterial 3D printing: challenges, solutions and perspectives

Abstract Multimaterial (MM) 3D printing shows great potential for application in metamaterials, flexible electronics, biomedical devices and robots, since it can seamlessly integrate distinctive materials into one printed structure. Among numerous MM 3D printing technologies, digital light processing (DLP) MM 3D printing is compatible with a wide range of materials from hydrogels to ceramics, and can print MM 3D structures with high resolution, high complexity and fast speed. This paper introduces the fundamental mechanisms of DLP 3D printing, and reviews the recent advances of DLP MM 3D printing technologies with emphasis on material switching methods and material contamination issues. It also summarizes a number of typical examples of DLP MM 3D printing systems developed in the past decade, and introduces their system structures, working principles, material switching methods, residual resin removal methods, printing steps, as well as the representative structures and applications. Finally, we provide perspectives on the directions of the further development of DLP MM 3D printing technology.

Advancements in DLP 3D printing: High strength alumina toughened zirconia ceramics for biomedical applications

Digital Light Processing (DLP) enables intricate ceramic part production from photosensitive ceramic slurry. While ZrO2 and Al2O3 are commonly studied, their composites are underexplored despite diverse applications. This study investigates fabricating high-strength, fully dense alumina-toughened zirconia (ATZ) parts using a low-cost desktop DLP printer designed for polymer printing. Various ATZ-based ceramic slurries (30, 35, 42.5 vol%) with different binders and dispersants were prepared and evaluated for curing and rheological properties. Promising formulations underwent debinding and sintering, resulting in homogenous microstructures with a well-distributed blend of the two phases. For the doped samples, SEM analysis revealed a good distribution of dopants and elongated dopant grains infused at higher temperatures. The 35 vol% ATZ exhibited exceptional average flexural strength of 1321 MPa, surpassing previous DLP-fabricated composites. This suggests no need for increased solid loading content. The findings demonstrate the potential of DLP in producing high-performance ceramic parts with tailored properties.

Advancements in developing biomaterials for 3D printing photosensitive resins containing quaternary ammonium molecules for enhanced oral healthcare

In this study, we investigated the development of biomaterials tailored for UV-cured 3D printing technology in oral healthcare. Traditionally, 3D-printed oral healthcare products have exhibited imperfections in antimicrobial and anti-pollution properties, limiting their utility. To address this challenge, we synthesised antimicrobial agents incorporating quaternary ammonium groups through a combination of isophorone diisocyanate (IPDI), hydroxyethyl methacrylate (HEMA), and choline chloride. These agents were then blended with diluents, resins, and photoinitiators to create raw materials suitable for UV-curing 3D printing photosensitive resins. Subsequently, the resins were subjected to digital light processing (DLP) 3D printing for curing. The resulting 3D-printed material underwent rigorous mechanical and antimicrobial testing. Our findings demonstrate that the 3D printed compounds, cured through this process, exhibited exceptional hardness, tensile properties, antimicrobial characteristics, and long-lasting antimicrobial durability. These developments promise widespread adoption and application within the oral healthcare field.

Fabrication of High Thermal Conductivity Aluminum Nitride Ceramics via Digital Light Processing 3D Printing.

The sintering of high-performance ceramics with complex shapes at low temperatures has a significant impact on the future application of ceramics. A joint process of digital light processing (DLP) 3D printing technology and a nitrogen-gas pressure-assisted sintering method were proposed to fabricate AlN ceramics in the present work. Printing parameters, including exposure energy and time, were optimized for the shaping of green bodies. The effects of sintering temperature, as well as nitrogen pressure, on the microstructure, density, and thermal conductivity of AlN ceramics were systematically discussed. A high thermal conductivity of 168 W·m-1·K-1 was achieved by sintering and holding at a significantly reduced temperature of 1720 °C with the assistance of a 0.6 MPa nitrogen-gas pressure. Further, a large-sized AlN ceramic plate and a heat sink with an internal mini-channel structure were designed and successfully fabricated by using the optimized printing and sintering parameters proposed in this study. The heat transfer performance of the ceramic heat sink was evaluated by infrared thermal imaging, showing excellent cooling abilities, which provides new opportunities for the development of ceramic heat dissipation modules with complex geometries and superior thermal management properties.

Fabrication of 3D-printed GNP/TiO2/epoxy composites: an investigation on mechanical and photocatalytic properties

Purpose Three-dimensional (3D) printing is popular for many applications including the production of photocatalysts. This paper aims to focus on developing of 3D-printed photocatalyst-nano composite lattice structure. Digital light processing (DLP) 3D printing of photocatalyst composites was performed using photosensitive resin mixed with 0.5% Wt. of TiO2 powder and varying amounts (0.025% Wt. to 0.2% Wt.) of graphene nanoplatelet powder. The photocatalytic efficiency of DLP 3D-printed photocatalyst TiO2 composite was investigated, and the effects of nano graphite powder incorporation on the photocatalytic activity, thermal and mechanical properties were investigated. Design/methodology/approach Methods involve 3D computer-aided design modeling, printing parameters and comprehensive characterization techniques such as structural equation modeling, X-ray diffraction, thermogravimetric analysis, Fourier-transform infrared (FTIR) and mechanical testing. Findings Results highlight successful dispersion and characteristics of TiO2 and graphene nanoplatelet (GNP) powders, intricate designs of 3D-printed lattice structures, and the influence of GNPs on thermal behavior and mechanical properties. Originality/value The study suggests applicability in wastewater treatment and environmental remediation, showcasing the adaptability of 3 D printing in designing effective photocatalysts. Future research should focus on practical applications and the long-term durability of these 3D-printed composites. Graphical abstract

Synthesis of Bio-Based Polyester Resins for Vat Photopolymerization 3D Printing.

Driven by environmental considerations, the scientific community has directed great effort towards the synthesis of new materials derived from renewable resources. However, for photocurable resins, most commercially available building blocks still rely on petroleum-based precursors. Herein, we present a simple synthesis route for bio-based acrylate-modified polyester resins, whose viscosity is sufficiently low for processing them with vat photopolymerization 3D printing. The established synthesis route enables the gradual substitution of fossil-based raw materials with bio-based alternatives. The acid number, color and viscosity of the bio-based acrylic resins are characterized and photocurable formulations are prepared by adding a radical photoinitiator. The photopolymerization kinetics, and thermomechanical and mechanical properties of the photopolymers are investigated as a function of the resin structure and benchmarked against a commercially available petroleum-based counterpart. Finally, the processability of the new bio-based resins via digital light processing 3D printing is demonstrated and test specimens are successfully 3D printed with a resolution in the millimeter range.

Optimizing polymer composite dielectric properties via digital light processing 3D printing of ordered barium titanate skeleton

Through construction of a three-dimensional continuous ceramic network, the dielectric performance of polymer composites can be enhanced with a reduced amount of ceramic loading. However, the commonly employed methods, such as freeze casting or sacrificial template, fail to precisely control the structure of the ceramic skeleton, leading to significant randomness in content control. In this work, a Digital Light Processing (DLP) 3D printing technique is utilized to precisely fabricate ordered three-dimensional ceramic structures, which are further sintered at high temperatures to obtain a continuous barium titanate (BT) skeleton (BTS). This is then compounded with cyanate ester based polymers (CP) to prepare BTS/CP composites. Results show that when the content of BT is 61.2 vol%, the dielectric constant of the composite is 657 at 100 Hz, which is about 173 times higher than CP, while maintaining a lower dielectric loss of 0.026. Interestingly, the distribution of BTS in the composites has a significant impact on the dielectric performance of the composite. When the BT content is about 50 vol%, the dielectric constant of the “fine and dense” skeleton composite is 2.1 times higher than that of the “coarse and sparse” skeleton composite. This study proposes a novel strategy for building a structurally and compositionally controllable three-dimensional barium titanate (BT) network within polymers, demonstrating the noteworthy influence of macrostructure on the dielectric performance of polymer composites. This offers a fresh approach to the mass application of ordered three-dimensional ceramic skeleton enhanced polymer composites in the fields of electronics and electricity.

Microarray Platforms Based on 3D Printing.

This paper introduces an innovative method for the fabrication and infusion of microwell arrays based on digital light processing (DLP) 3D printing. A low-cost DLP 3D printer is employed to fabricate microstructures rapidly with a broad dynamic range while maintaining high precision and fidelity. We constructed microwell arrays with varying diameters, from 200 to 2000 μm and multiple aspect ratios, in addition to microchannels with widths ranging from 45 to 1000 μm, proving the potential and flexibility of this fabrication method. The superimposition of parallel microchannels onto the microwell array, facilitated by positive or negative pressure, enabled the transfer of liquid to the microwells. Upon removal of the microchannel chip, a dispensed microdroplet array was obtained. This array can be modulated by adjusting the volume of the microwells and the inflow fluid. The filled microwell array allows chip-to-chip dispensing to the microreactor array through binding and centrifugation, facilitating multistep and multireagent assays. The 3D printing approach also enables the fabrication of intricate cavity designs, such as micropyramid arrays, which can be integrated with parallel microchannels to generate spheroid flowcells. This device demonstrated the ability to generate spheroids and manipulate their environment. We have successfully utilized precise modulation of spheroids size and performed parallel drug dose-response assays to evaluate its effectiveness. Furthermore, we managed to execute dynamic drug combinations based on a compact spheroids array, utilizing two orthogonal parallel microchannels. Our findings suggest that both the combination and temporal sequence of drug administration have a significant impact on therapeutic outcomes.

Excellent microwave absorption property of 3D printed SiCN matrix metamaterial

The combination of 3D printing, polymer derived ceramics, and electromagnetic wave (EMW) absorption metamaterials is particularly useful for spacecraft stealth in extreme environments and is gradually gaining significant interest. While the 3D printing of SiOC has been extensively researched, the high temperature stability and mechanical performance of SiOC are not as favorable as SiCN. However, it remains challenging to prepare SiCN metamaterials with both high mechanical and microwave absorption properties by 3D printing. Herein, we demonstrate a SiCN EMW absorption metamaterial with high mechanical properties using digital light processing 3D printing, which achieves a minimum reflection loss of −31.01 dB (99.9 % absorption), and the widest effective absorption bandwidth covers the entire X-band from 8.2 to 12.4 GHz. And the EMW absorption performance can be adjusted based on the size of the unit structure.

Lightweight, ultra-broadband SiOC-based triply periodic minimal surface meta-structures for electromagnetic absorption

Lightweight wide-band ceramic-based electromagnetic (EM) absorbers have a great application demand in the field of high-temperature EM wave absorption. However, it is difficult for traditional ceramic-based structural EM absorbing materials (EMAMs) to balance the contradiction between broadband absorption and good impedance matching due to resonance effect. Herein, three novel non-resonant SiOC-based triply periodic minimal surface (TPMS) meta-structures named Schoen G (SG), Schwarz D (SD) and Schwarz P (SP) with a density of 0.556 g/cm3 were successfully synthesized by digital light processing (DLP) 3D printing and polymer-derived ceramics (PDCs) method. Through the structural design of multilayer arrays and holes, three metamaterials achieve good impedance matching and broadband EM absorption. The effective absorption bandwidth (EAB) of all three meta-structures reaches 9.80 GHz (8.2–18.0 GHz) in a wide matching thickness range, covering the entire X-Ku band. In addition, the minimum reflection loss (RLmin) of −55.68 dB is obtained at a matching thickness of 3.02 mm for SD meta-structure in X-band. Besides, the SG meta-structure tested by the arch method has an ultra-wide EAB of 11.88 GHz (6.12–18.0 GHz), exhibiting ultra-broadband EM absorption properties. It is significant that the intrinsic relationships between TPMS meta-structures and EM responses are explored by CST simulation. This work provides a new perspective for the design of lightweight, broadband ceramic-based EM metamaterial absorbers under high-temperature, harsh environments.

Influences of two sizes of nano-Fe3O4 on stereolithography 3D printing properties of gel photoresist for photothermal-responsive hydrogel

Nanocomposite hydrogels enable augmented properties, functions, and responsive behaviors. In the field of stereolithography 3D printing of the photothermal responsive nanocomposite hydrogel, the influence of the size of nano-Fe3O4 on 3D printing properties is significant due to the sedimentation, but the relevant research is rare. In this study, for the fabrication of photothermal responsive hybrid hydrogel, poly(N-isopropylacrylamide-acrylamide)/nano-Fe3O4 [P(NIPAM-AM)/nano-Fe3O4] gel photoresist was prepared and digital light processing (DLP)-based 3D printing as one of the popular stereolithography 3D printing technology was utilized. The influences of two sizes of Fe3O4 nanoparticles (10 and 50nm) denoted as nano-Fe3O4(10) and nano-Fe3O4(50) on DLP 3D printing properties of the gel photoresist were investigated in detail. The results reveal that the gel photoresist with nano-Fe3O4(10) obtained long exposure time for the basic prototype, low overcuring degree (Od), and good uniformity of nanoparticles in hybrid hydrogels, while those with nano-Fe3O4(50) had the merits of printing high 3D sample due to the low release fore. Unfortunately, the gel photoresist with a high content of nano-Fe3O4 such as 3.11wt% failed in 3D printing of a high and uniform gel cylinder. A strategy of preparing P(NIPAM-AM)/nano-Fe3O4 gel photoresist with mixed nano-Fe3O4(10) and (50) for 3D printing was proposed. Using the gel photoresist (nano-Fe3O4 content: 3.11wt%) with two sizes of nano-Fe3O4 mixed with 50% each and the exposure time of 8s, a gel cylinder with a height of 1cm was successfully printed with uniform nano-Fe3O4 distribution and low Od values (≤ 1.17%). Further, a biomimetic hydrogel octopus was 3D printed by using the gel photoresist with mixed nano-Fe3O4 and thereafter a near-infrared-light-driven waving motion of octopus tentacle was achieved successfully.

Three-Dimensional-Printed GelMA-KerMA Composite Patches as an Innovative Platform for Potential Tissue Engineering of Tympanic Membrane Perforations.

Tympanic membrane (TM) perforations, primarily induced by middle ear infections, the introduction of foreign objects into the ear, and acoustic trauma, lead to hearing abnormalities and ear infections. We describe the design and fabrication of a novel composite patch containing photocrosslinkable gelatin methacryloyl (GelMA) and keratin methacryloyl (KerMA) hydrogels. GelMA-KerMA patches containing conical microneedles in their design were developed using the digital light processing (DLP) 3D printing approach. Following this, the patches were biofunctionalized by applying a coaxial coating with PVA nanoparticles loaded with gentamicin (GEN) and fibroblast growth factor (FGF-2) with the Electrohydrodynamic Atomization (EHDA) method. The developed nanoparticle-coated 3D-printed patches were evaluated in terms of their chemical, morphological, mechanical, swelling, and degradation behavior. In addition, the GEN and FGF-2 release profiles, antimicrobial properties, and biocompatibility of the patches were examined in vitro. The morphological assessment verified the successful fabrication and nanoparticle coating of the 3D-printed GelMA-KerMA patches. The outcomes of antibacterial tests demonstrated that GEN@PVA/GelMA-KerMA patches exhibited substantial antibacterial efficacy against Staphylococcus aureus, Pseudomonas aeruginosa, and Escherichia coli. Furthermore, cell culture studies revealed that GelMA-KerMA patches were biocompatible with human adipose-derived mesenchymal stem cells (hADMSC) and supported cell attachment and proliferation without any cytotoxicity. These findings indicated that biofunctional 3D-printed GelMA-KerMA patches have the potential to be a promising therapeutic approach for addressing TM perforations.

Evolution of Self‐Assembled Lignin Nanostructure into Dendritic Fiber in Aqueous Biphasic Photocurable Resin for DLP‐Printing

AbstractThe design of lignin nanostructures where interfacial interactions enable enhanced entanglement of colloidal networks can broaden their applications in hydrogel‐based materials and light‐based 3D printing. Herein, an approach for fabricating surface‐active dendritic colloidal microparticles (DCMs) characterized by fibrous structures using nanostructured allylated lignin is proposed for the development of lignin‐based photocurable resins. With allyl‐terminated surface functionality of 0.61 mmol g−1, the entanglement between lignin‐DCM fibrils with a size of 1.4 µm successfully produces only lignin‐based hydrogels with structural integrity through photo‐crosslinking. The colloidal network of lignin dendricolloids reinforces the poly(ethylene glycol) (PEG) hydrogels during a digital light processing (DLP) 3D printing process by generating bicontinuous morphologies, resulting in six‐fold increases in toughness values with respect to the neat PEG hydrogel. The dual effectiveness of photoabsorption and free‐radical reactivity of lignin‐DCMs allow the light‐patterning of rather dilute PEG hydrogels (5–10%) with high geometric fidelity and structural complexity via DLP 3D printing. This study demonstrates a green and effective strategy for the design of 1D lignin‐DCMs that increases the versatility of the nanostructured biopolymer, opening up numerous opportunities for formulating functional hydrogels with robust structure‐property correlations.

AutoML-driven diagnostics of the feeder motor in fused filament fabrication machines from direct current signals

AbstractPart defects in additive manufacturing are more frequent compared to machining or molding. Failures can go unnoticed for hours, wasting resources and extending process cycle times. This paper describes a Machine Learning based method for automated sensing of onset failure in additive manufacturing machinery. Investigations are conducted on a Fused Filament Fabrication (FFF) 3D printer, and the same methods are then applied to a digital light processing 3D printer. The investigation focuses on signal-based analysis, specifically passive sensing of stepper motors relating DC current measurements to the torque on a stepper, as opposed to any active acoustic interrogation of the part. Passive methods are used to characterize the loading on a feeder stepper in an FFF machine, forming a model that can identify early signs of filament-based failure with 85.65% 10-fold cross-validation accuracy. Efforts show filament breakage can be detected minutes before material runout would cause a defect, allowing ample time to pause, correct, or control the print. The machine learning pipeline was not naively conceived but optimized through automated machine learning.

Investigation of sound absorption on a polymeric acoustic metamaterial using 3D printing process

AbstractThis paper presents the design and characterization of DENORMS (Designs for Noise‐Reducing Materials and Structures) cell‐based acoustic metamaterial developed using a 3D printing technique. The metamaterial's acoustic absorption properties were investigated through experimental testing and numerical simulations. The experimental testing of the acoustic metamaterial was conducted in an impedance tube using a two‐microphone method. The numerical simulations were carried out using a thermoviscous module. The simulations allowed for a deeper understanding of the influence of geometric parameters on the absorption coefficient, providing valuable insights for optimizing the design. It was observed that upon increasing the spherical diameter while maintaining the same cylindrical diameter and cylindrical length resulted in an increase in the absorption coefficient throughout the frequency range. It was also observed that upon increasing the cylindrical diameter, there was a significant decrement of absorption coefficient, and upon increasing the length of the cylinder, there was a shift of response toward lower frequency. The augmentation in cell count from 9 to 24 led to a rise in the absorption coefficient and a shift of the response toward lower frequencies. The findings highlight the significance of photopolymer 3D printing in tailoring complex geometries for enhanced performance of the acoustic metamaterial.Highlights Photopolymeric resin used for DENORMS cell‐based acoustic metamaterial. High cleanability and accuracy of digital light processing 3D printing technique. Usage of thermoviscous model for simulation of sound absorption behavior. Use of two microphone impedance tube to determine sound absorption coefficient. Geometric parameters significantly affect the absorption coefficient.

Experimental investigation and optimization of process parameters on digital light processing (DLP) 3D printing process based on Taguchi-grey relational analysis

Additive manufacturing technology, specifically Digital Light Processing (DLP), offers a unique approach to fabricating intricate objects without the need for traditional molds or machining. The technique described entails the incremental construction of layers through the curing process polymer, facilitated by a projection light source. Digital Light Processing 3D printing is particularly suited for creating complex structures with small cross-sections, requiring high surface polish and durability. In this study, DLP-printed test coupons were produced using an Ultraviolet-sensitive resin, and the investigation focused on examining the impact of surface quality and toughness, adhering to guidelines outlined by the ASTM specifications. To optimize the DLP printing process, Taguchi and Grey relational optimization techniques were employed to find the best values for multiple factors. The parameters considered in this study were speed, layer thickness, orientation, and pattern type. By employing these techniques, the optimal parameters were identified as follows: The printing process is conducted at a speed of 3 mm per second, with each layer being 0.05 mm thick and the orientation of the printed object is set at 90 degrees, and the pattern employed is of the square type. Experimental results revealed that utilizing these parameters yielded a surface roughness of 2.58 µm and an impact strength of 9.1J. The results showed that the Grey relational grade improved from 0.6244 to 0.7974, with a deviation of 0.173 and 27.71%, indicating a significant enhancement in the optimization process. Additionally, contour plots depicting the relationships between speed and orientation, speed and layer thickness, and orientation and layer thickness were generated for surface roughness, impact strength, and the Grey relational grade. This research offers valuable insights into optimizing DLP 3D printing processes to achieve enhanced surface quality, toughness, and material efficiency while reducing costs and production time.

Flame Retardant Additives in Polylactic Acid (PLA) Photopolymer Resin for 3D Printing Digital Light Processing (DLP)

Digital light processing (DLP) technology has been developed based on stereolithography (SLA) 3D-printing principle. The biodegradable and low-cost polylactic-acid (PLA) has so far been used as polymeric material for photopolymer resin in SLA and DLP. To achieve functional SLA-processed product, the properties of such PLA has been improved, with the aim to make it flame retardant, less viscous, and having light transmittance characteristics. In this study, the liquid raw PLA photopolymer was changed by adding different contents of Ammonium Phosphate (APP), melamine cyanurate (MCA), Aluminum Tri-hydroxide (Al2O3) and Nano-silicon dioxide (SiO2) additives. The solid PLA nanocomposite specimens were printed by using DLP device according to the standard geometry for burning test UL-94 to evaluate its flame-retardant property. In addition, the printing product and residue after burning test was analyzed for their morphological characteristic by using SEM. The results showed that the low weight fraction of MCA showed excellent performance. PLA/MCA successfully kept green body form until the sintering temperature of stainless steel was achieved. It can become a reference for application DLP 3D printing products in the casting and sintering process.

Digital light processing 3D printing of microfluidic devices targeting high-pressure liquid-phase separations.

This paper focuses on 3D printing using digital light processing (DLP) to create microchannel devices with inner diameters of100, 200, and 500 µm and cater flow-through applications within the realm of analytical chemistry, in particular high-pressure liquid chromatographic separations. Effects of layer thickness and exposure time on channel dimensions and surface roughness were systematically investigated. Utilizing a commercially accessible 3D printer and acrylate resin formulation, we fabricated 100-500 µm i.d. squared and circular channel designs minimizing average surface roughness (< 20%) by applying a 20-µm layer thickness and exposure times ranging from 1.1 to 0.7s. Pressure resistance was measured by encasing microdevices in an aluminum chip holder that integrated flat-bottom polyetheretherketon (PEEK)nanoports allowing to establish the micro-to-macro interface to the HPLC instrument. After thermal post-curing and finetuning the clamping force of the chip holder, a maximum pressure resistance of 650bar (1.5% RSD) was reached (n = 3). A polymer monolithic support structure was successfully synthesized in situ with the confines of a 500 µm i.d. 3D printed microchannel. A proof-of-concept of a reversed-phase chromatographic gradient separation of intact proteins is demonstrated using an aqueous-organic mobile-phase with isopropanol as organic modifier.

Digital light 3D printing of artificial bone with star-shaped polycaprolactone-based polyurethane acrylate

Advanced medical materials and manufacturing technologies are highly in demand in artificial bones. Herein, a four-arm star-shaped polycaprolactone polyurethane acrylate (FPCLA) was designed and synthesized. The photosensitive character of FPCLA contributed to the rapid prototyping and personalized customization under digital light processing (DLP) 3D printing technology. The FPCLA was prepared by introducing unsaturated double bonds into polycaprolactone tetraethyl alcohol (PCLT). We characterized the physico-chemical properties of the material through FTIR, H-NMR, GPC, DSC and SEM. Cell behaviors on material were observed in vitro. In addition, we employed a DLP 3D printer to evaluate the feasibility of FPCLA to fabricate artificial bone model. The photocuring star polycaprolactone was confirmed in detail by detection method. SEM analyses demonstrated that FPCLA has good tenacity. The material can be used to fabricated artificial bone with a diameter of 3.02 mm at its narrowest by DLP 3D printing technology. The cell survival rates of CCK-8 and Live/Dead fluorescence staining experiments were both above 90%, which indicated safety and feasibility of such new-generation artificial bone made of synthetic polymers.

Multiscale design and digital light processing preparation of high-strength SiOC ceramic metastructures for tuning microwave absorption properties

Silicon oxycarbide (SiOC) ceramics have been used to fabricate microwave-absorbing metastructures, demonstrating impressive absorption capabilities. However, SiOC ceramic metastructures with excellent performance require simple fabrication processes and appropriate mechanical and electromagnetic properties. In this study, a solvent-free photosensitive polysiloxane preceramic was developed by blending methoxy/hydroxy polysiloxanes with acrylates, with a ceramic yield of over 60% after curing using a novel two-step ultraviolet (UV)/thermal method. The composition and microstructure of SiOC ceramics can be designed by controlling the preceramic composition. Dense, crack-free gyroid-shellular shaped triple periodic minimal surface (GS-TPMS) electromagnetic metastructures were fabricated using digital light processing (DLP) 3D printing technology. By designing the porosity of the GS-TPMS structure to 51%, an effective absorption bandwidth that covers the X-band can be achieved at a thickness of 3.1 mm. The honeycomb structure, with a geometric density of 0.69 g/cm3, exhibited a high compressive strength of 107.05 MPa. This paper presents an efficient approach for the prompt and customized fabrication of lightweight ceramic metastructures with outstanding microwave absorption properties.