Coupling 3D printing and SPS sintering for the fabrication of ultra-refractory materials with complex shapes – ULTRACOMPLEX

This project aims to enable the fabrication of complex high-performance ceramic shapes by combining ceramic additive manufacturing (AM) and Spark Plasma Sintering (SPS). This AM-SPS coupling will leverage the high resolutions of parts printed via stereolithography (SLA) and the ability of SPS to sinter high-performance ceramics, such as ultra-high-temperature ceramics. Seven patents have been filed over the past three years for this concept, and very promising results have already been obtained for metals. To validate this concept for ultra-refractory ceramics sintered at temperatures close to 2000°C, the project will focus on the fabrication of complex shapes in pure ZrB2 (melting point >3000°C) with B4C/C additives. These shapes, which are very difficult to machine, will have exceptional thermal properties due to the very low content of additives. Our project will enable the fabrication of these ceramics in complex shapes by relying on the latest printed graphite interfaces, for which we have recently mastered SLA printing for small parts. The new opportunities as well as the limitations of this concept will be clearly established through this project.