Researchers at Purdue Applied Research Institute (PARI) are exploring methods to 3D print dark ceramics, enabling complex, heat-resistant components for hypersonic vehicles.
Their objective is to develop complex shapes for hypersonic vehicle components while improving scalability and efficiency. Led by Professor Rodney Trice from Purdue’s School of Materials Engineering, the team is using Digital Light Processing (DLP) to adapt these ceramics for additive manufacturing. This 3D printer is housed at PARI’s Hypersonics Advanced Manufacturing Technology Center (HAMTC).
“Because dark powders absorb the UV light that would be necessary to cure the material, we cannot form as thick of a layer,” said Trice. “Therefore, we get cure depths that are too thin, which then negatively impacts the time it takes to build each part.”
Overcoming challenges in 3D printing dark ceramics
According to Trice, this approach enables the creation of intricate designs with exceptionally smooth surfaces and micron-level precision. His team has successfully printed a variety of shapes, including sharp cones and hemispheres, both crucial components in hypersonic vehicle design.
But the process isn’t without challenges. Unlike lighter-colored ceramics, which reflect and scatter UV light to cure evenly, dark ceramics absorb light, making it harder to solidify each layer properly. To tackle this, Trice, along with doctoral candidate Matthew Thompson and ceramics research engineer Dylan Crump, is experimenting with different resin formulations and surface treatments to enhance the curing process.
Thompson has described the team’s work as an ongoing effort to refine the material properties and printing process. He explained that the researchers have been modifying the ceramics to enhance their printability while also addressing challenges in post processing. These include delamination and cracking, issues that become more pronounced with larger components.
As the project progresses, scaling up production remains a key focus. Moving from small-scale to large-scale manufacturing presents additional risks, and the team is working to mitigate these challenges.
Thompson has emphasized that their aim is to “either set up a pipeline to make these parts or find strategies that actual stakeholders can use.” This would further help in reducing the time and effort required for research and development (R&D) in similar applications.
As per the team, this research is part of a broader initiative supported by the Office of the Secretary of Defense Manufacturing Science and Technology Program. It is being conducted in alliance with the Naval Surface Warfare Center, Crane Division, and the National Security Technology Accelerator’s Strategic and Spectrum Missions Advanced Resilient Trusted Systems.
The findings are expected to contribute to the broader adoption of advanced ceramics in hypersonic vehicle development, bridging the gap between research and real-world application.
High-performance ceramics for hypersonic vehicles
Previous news highlighted the use of ceramics as ideal for hypersonic applications due to their ability to endure extreme heat and pressure while supporting the scalable production of complex, high-precision components.
Few years back, the U.S. Air Force (USAF) was exploring 3D printed ceramics for hypersonic flight, by working with HRL Laboratories under a Collaborative Research and Development – Material Transfer Agreement (CRADA-MTA). This research focused on silicon oxycarbide (SiOC), a ceramic capable of withstanding extreme temperatures up to 3,200°F while enabling complex geometries through 3D printing.
Scientists at the Aerospace Systems Directorate (ASD) tested SiOC components, including thermocouple radiation shields, to evaluate their structural integrity under hypersonic conditions. For this research, the material was initially printed as a pre-ceramic resin and then heat-treated to form a fully ceramic structure. The CRADA-MTA enabled the Air Force to provide research insights while HRL retained patent rights, supporting further exploration of hypersonic technology.
In 2016, Imperial College London (ICL) researchers identified tantalum carbide and hafnium carbide as refractory ceramics with the highest recorded melting points, reaching 4000°C. This discovery had the potential to enhance thermal protection structures for hypersonic vehicles, which experience extreme heat exceeding 2200K at their nose tips and leading edges due to velocities above Mach 5.
Known for their heat resistance, these ceramics complement advanced manufacturing techniques like 3D printing and ceramic matrix composites used in jet engines, improving efficiency and durability in high-temperature environments. The study was published in Scientific Reports.
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Featured image shows Matthew Thompson loading a crucible into a box furnace to heat and removing binders from 3D printed ceramic samples. Photo via PARI.
