3D Printing Bioinspired Ceramics from Preceramic Polymers
YAZDANI SARVESTANI H. 1, SHASHOUA A. 1, SOHRABI KASHANI A. 1, LACELLE T. 2, JAKUBINEK M. 2, PAQUET C. 2, ASHRAFI B. 1
1 National Research Council Canada, Montreal, Canada; 2 National Research Council Canada, Ottawa, Canada
Ceramic materials have high mechanical strength and exceptional environmental stability, but are suboptimal for structural applications due to their inherent brittleness and low damage tolerance. Polymer-derived ceramics can address the shape constraints and limitations of many traditional ceramics processing techniques. These can enable near-net-shape manufacturing of complex geometry parts through the use of polymer precursors which are subsequently converted to a ceramic. Polymer additive manufacturing (3D printing) methods are a particularly versatile approach, offering the possibility to print high complexity shapes and customization. These methods have recently been applied to polymer-derived ceramics. In this paper, we describe the formulation of a commercial silicon oxycarbides (SPR 684), which is typically polymerized via thermal cure, for photopolymerization and 3D printing via stereolithographic (SLA) printing. The preceramic polymer is combined with a photoinitiator, crosslinkers and other additives, which enabled the definition of different shapes via SLA. The printed polymer was subsequently pyrolyzed in nitrogen, leaving a polymer-derived ceramic with a shape determined by the printed polymer. The partially optimized, printed ceramic was equivalent in density to samples produced by the conventional thermal cure process. However, in both cases the samples suffered from quality issues such as porosity due to gaseous byproducts released in the pyrolysis. Through computed tomography imaging and compression experiments, we reveal that the effect of formulation components play a role in crack initiation and propagation of the 3D-printed architectures. The method is particularly suited to producing relatively thin features and customized structures, which is promising for the production and study of bio-inspired, architected ceramic structures via low-cost SLA 3D printing.