Organic precursor synthesis method combined with 3D printing

Silicon carbide (SiC) ceramics have enormous application space in fields such as semiconductors, energy, aerospace, catalysts, etc. Among them, SiC porous ceramics with high porosity have lighter weight, larger specific surface area, and higher porosity due to their unique structure. These excellent characteristics also make them play an important application value in many fields such as insulation, gas separation, high-temperature reactors, electromagnetic shielding, and catalyst carriers.

However, traditional manufacturing technologies such as dry pressing, injection molding, and strip casting often face enormous difficulties for the manufacturing of complex shaped SiC ceramics - not only is the process complex, time-consuming, and the preparation cycle long, but also the raw materials and manufacturing costs are high. In addition, defects such as pores, cracks, and unevenness during the forming process make it difficult to avoid brittle fracture of ceramic devices, seriously restricting the full utilization of their mechanical properties and limiting our ability to fully utilize the excellent properties of SiC materials such as high temperature resistance and corrosion resistance.

Starting from the organic precursors of SiC ceramics and utilizing the latest 3D printing ceramic technology, not only can the difficulties of preparing complex ceramic devices using SiC powder be overcome, but also the defects that occur during the ceramic material forming process can be solved. Its emergence has opened up a new path for the application of SiC materials.

Organic precursor conversion ceramic (PDC), also known as polymer derived ceramic, refers to the ceramic material obtained by utilizing the easy processing properties of organic polymer precursors to obtain the desired shape, and then undergoing high-temperature conversion to obtain the desired ceramic material. The organic precursor conversion method can be divided into four steps, including molding, crosslinking, pyrolysis, and crystallization. The polymer is first formed by 3D printing, photocuring, cross-linking, and finally pyrolysis. Through a set heating program, the precursor gradually splits and generates ceramics. During the pyrolysis process, some volatile compounds are released, and the organic parts are decomposed to form inorganic materials.

SiC ceramic materials prepared by precursor conversion can be applied in many high-end technology and defense military fields, with broad application prospects, such as aviation engines, aircraft thermal protection systems, weapons and equipment, space mirror supports, and other SiC composite materials used in extreme environments; Porous SiC with impact resistance, separation, insulation, adsorption or catalyst loading properties; Connection or crack repair between ceramics and ceramic matrix composites, etc.