Molecule editable 3D printed polymer-derived ceramics

Achieving High-Temperature Stable Structural Color through Nanostructuring in Polymer-Derived Ceramics

Structural colors offer a myriad of advantages over conventional pigment-based colors, which often rely on toxic chemical substances that are prone to UV degradation. To take advantage of these benefits in demanding environments, there is growing interest in producing structural colors from ceramics. Polymer-derived ceramics (PDCs) emerge as a compelling choice, presenting two distinct advantages: their enhanced shape ability in their polymeric state associated with impressive temperature resistance once converted to ceramics. This study pioneers the fabrication of noniridescent structural colors from silicon oxycarbide (SiOC) PDC, enabled by the nanostructuring of an inverse photonic glass within the PDC material. This design, a functionally graded material with an inverse photonic glass (FGM-PhG) structure, leverages the innate light-absorbing properties of SiOC, yielding a vivid structural color that maintains its saturation even in white surroundings. This study elucidates the process-structure-properties relationship for the obtained structural colors by investigating each layer of the functionally graded material (FGM) in a stepwise coating deposition process. To further emphasize the exceptional processing flexibility of PDCs, the three-step process is later transferred to an additive manufacturing approach. Finally, the FGM-PhG structural colors are demonstrated to have remarkable thermal stability up to 1000 °C for 100 h, possibly making them the most thermally stable ceramic structural colors to date.

Programmable and Modularized Gas Sensor Integrated by 3D Printing

The rapid advancement of intelligent manufacturing technology has enabled electronic equipment to achieve synergistic design and programmable optimization through computer-aided engineering. Three-dimensional (3D) printing, with the unique characteristics of near-net-shape forming and mold-free fabrication, serves as an effective medium for the materialization of digital designs into usable devices. This methodology is particularly applicable to gas sensors, where performance can be collaboratively optimized by the tailored design of each internal module including composition, microstructure, and architecture. Meanwhile, diverse 3D printing technologies can realize modularized fabrication according to the application requirements. The integration of artificial intelligence software systems further facilitates the output of precise and dependable signals. Simultaneously, the self-learning capabilities of the system also promote programmable optimization for the hardware, fostering continuous improvement of gas sensors for dynamic environments. This review investigates the latest studies on 3D-printed gas sensor devices and relevant components, elucidating the technical features and advantages of different 3D printing processes. A general testing framework for the performance evaluation of customized gas sensors is proposed. Additionally, it highlights the superiority and challenges of programmable and modularized gas sensors, providing a comprehensive reference for material adjustments, structure design, and process modifications for advanced gas sensor devices.

Flexural strength and translucency of barium-silicate-filled resin nanoceramics for additive manufacturing

OBJECTIVE

This in vitro study aimed to evaluate the flexural strength (FS) and translucency parameter (TP) of resin nanoceramics (RNCs) with barium silicate for additive manufacturing.

MATERIALS AND METHODS

An RNC slurry was prepared by mixing a barium silicate filler and resin monomer. For the FS tests, specimens with three filler contents (0, 50, and 63 wt%) were designed according to ISO6872 for dental ceramics and ISO10477 for dental polymers. These specimens were then formed into discs with thicknesses of 1 and 2 mm for TP measurement.

RESULTS

In the specimens prepared according to ISO6872, the FS increased significantly depending on the filler content. However, in the case of ISO10477, there was no significant difference between the FSs of the specimens with 0 and 50 wt% filler contents. The increase in thickness affected translucency, and the lowest translucency was obtained at a filler content of 63 wt%. The filler distribution was dense in the specimen with 63 wt% filler and uniform but relatively sparse in the specimen with 50 wt% filler. More voids were observed in the specimen with 63 wt% filler. The thickness and filler content of the specimen affected its TP. The TP of the specimen with 63 wt% filler was similar to that of human enamel.

CONCLUSION

The FS was significantly higher at a filler content of 63 wt%. The lowest translucency was obtained at a filler content of 63 wt% for all tested thicknesses.

CLINICAL SIGNIFICANCE

Increasing the filler content was advantageous for the mechanical properties of the RNCs. A high filler content led to low translucency in the RNCs. Therefore, the esthetics of human teeth can be reproduced if layering according to the filler content is performed in areas where esthetic characteristics are required.

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.

Additive Manufacturing of Advanced Ceramics Using Preceramic Polymers

Ceramic materials are used in various industrial applications, as they possess exceptional physical, chemical, thermal, mechanical, electrical, magnetic, and optical properties. Ceramic structural components, especially those with highly complex structures and shapes, are difficult to fabricate with conventional methods, such as sintering and hot isostatic pressing (HIP). The use of preceramic polymers has many advantages, such as excellent processibility, easy shape change, and tailorable composition for fabricating high-performance ceramic components. Additive manufacturing (AM) is an evolving manufacturing technique that can be used to construct complex and intricate structural components. Integrating polymer-derived ceramics and AM techniques has drawn significant attention, as it overcomes the limitations and challenges of conventional fabrication approaches. This review discusses the current research that used AM technologies to fabricate ceramic articles from preceramic feedstock materials, and it demonstrates that AM processes are effective and versatile approaches for fabricating ceramic components. The future of producing ceramics using preceramic feedstock materials for AM processes is also discussed at the end.

Design and Manufacturing of Si-Based Non-Oxide Cellular Ceramic Structures through Indirect 3D Printing

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.

Hierarchical Porous Carbon Nanofibers with Tunable Geometries and Porous Structures Fabricated by a Scalable Electrospinning Technique

Porous carbon nanofibers (PCNFs) have rich channels for transporting ions, molecules, and nanoparticles, but the control over their porous structures is a challenge. Here, we report a scalable electrospinning technique by using poly(tetrafluoroethylene) as a pore template, boric acid as a cross-linking agent, and polyvinyl alcohol and polyurethane as dual carbon precursors to fabricate flexible PCNFs with tunable geometries and macro/meso/microporous structures. In the water solvent, the negatively charged template cross-links with the positively charged carbon precursors to form a stable sol for electrospinning. By varying the mass ratios of these precursors, the electrospun hybrid nanofibers are directly transformed into B-F-N-O doped PCNFs with tunable macro-, meso-, and micropores after carbonization. The porosity of an individual PCNF is as high as ∼85%, and the pore volume can be tuned from 0.23 to 0.58 cm³·g^-1. When constructing high-sulfur-content (86 wt %) electrodes with the freestanding PCNF films, the porous structures with rich electroactive sites provide rapid pathways for poly-anions and have strong chemisorption of poly-sulfides, leading to a great electrochemical performance. The reported strategy offers a new perspective for synthesizing hierarchical PCNFs with appealing applications.

Infinite Approaching Superlubricity by Three-Dimensional Printed Structures

The rapid development of three-dimensional (3D) printing technology opens great opportunities for the design of various multiscale lubrication structures. 3D printing allows high customization of arbitrary complex structures and rapid prototyping of objects, which provides an avenue to achieve effective lubrication. Current experimental observations on superlubricity are limited to atomically smooth clean surfaces, extreme operating conditions, and nano- or microscales. With the in-depth exploration of 3D printed lubrication, construction of multifunctional 3D structures with refined dimensions spanning from micronanoscale to macroscale is increasingly regarded as an important means to approach superlubricity and has aroused great scientific interest. To document recent advances in 3D printing for structural lubrication, a detailed literature review is provided. Emphasis is given on the design and lubrication performance of geometric and bioinspired lubrication structures with characteristic dimensions. The material requirements, merits, drawbacks, and representative applications of various 3D printing techniques are summarized. Potential future research trends aiming at the design strategy and manufacturing process of 3D printed lubrication structures are also highlighted.