Materials

R&D Into 3D Printed Silicon Carbide

US Ceramics manufacturer Ceralink has developed a method for producing Silicon Carbide and composites using ExOne powder bed inkjet 3D printers, as part of a Phase II Small Business Innovation Research (SBIR) grant from the U.S. National Science Foundation (NSF). A layer of carbon powder is deposited by a 3D printer, then an inkjet printer is used to deposit an organic binder, pre-mixed with additional powder. This method produces a carbon preform, which is then converted to Silicon Carbide by ‘reaction bonding’ —  burning away the binder and adding liquid silicon under high pressure. 

The resulting material consists of silicon carbide fibers embedded in a fully dense Silicon Carbide matrix.

Black Silicon Carbide GrainCeralink says that the material offers lighter weight, higher temperature performance, and higher wear resistance than nickel alloys and titanium alloys for aerospace jet engine components. The ability to 3D print an increasingly wide range of materials to achieve required properties will continually test the limits of both the available equipment and process innovation – applications such as aerospace continue to demand lighter weight and higher performance, process development must continue in tandem with materials development.

By incorporating chemical modification post-processing steps into the production process, Ceralink is expanding the range of printable materials using existing printers and materials powders. Additional testing is required before Ceralink’s materials are brought to market, but its development strategy may be a useful insight for 3D printer manufacturers, materials developers, and users seeking to continue to improve the industrial utility of additive manufacturing technologies.’

About Ceralink

Ceralink is an independent, woman-owned small business that was founded in January 2000 by Dr. Holly S. Shulman. The company has developed a specialized team with materials expertise, process development and testing excellence. As Ceralink has expanded over the past 12 months, we have segmented our business into three distinct client-focused areas relating to ceramics and materials’ 
http://www.ceralink.com/about

Sources: Lux Research, Ceralink