CHEN Jiakun ^{1, 2}, CHEN Jian ¹, GAO Chenxi ^{1, 3}, HUANG Changcong ^{1, 3}, LIAO Shengjun ^{1, 3},

PENG Lan ^{1, 4}, CHEN Zhongming ¹, HUANG Zhengren ¹

(1. Shanghai Institute of Ceramics, Chinese Academy of Sciences, Shanghai 200050, China; 2. School of Materials Science and Engineering, Shanghai University, Shanghai 200444, China; 3. University of Chinese Academy of Sciences, Beijing 100049, China; 4. School of Physical Science and Technology, Shanghai Tech University, Shanghai 201210, China)

Extended abstract:

[Significance] Silicon carbide ceramics, due to their tetrahedral covalent bond structure formed through sp3 hybridization, exhibit exceptional properties, such as high hardness, excellent thermal conductivity, chemical stability and a low coefficient of thermal expansion. These characteristics make them indispensable in high-end fields, including aerospace, semiconductors, solar photovoltaics and the nuclear industry. However, the manufacturing processes for traditional silicon carbide ceramics face insurmountable challenges. The high hardness of silicon carbide complicates processing. Structural components are extremely difficult to shape, resulting in prolonged processing time, high costs and poor control over molding quality. In contrast, 3D printing technology offers a revolutionary solution. Binder jetting 3D printing (BJ-3D) enables the rapid manufacturing of silicon carbide ceramic components with complex shapes without the need for molds. This technology also boasts advantages, such as high material utilization and low production costs, effectively addressing the limitations of traditional processes. Furthermore, as compared with other 3D printing technologies, such as selective laser sintering (SLS), direct ink writing (DIW), stereolithography (SLA) and fused deposition modeling (FDM), BJ-3D stands out in aspects, such as no thermal deformation during the printing process, high molding efficiency and minimal differences in thermal expansion coefficients between materials. This makes it the most promising technology for large-scale production of silicon carbide ceramic components with large and complex structures, thus holding great significance for advancing the industrial application of silicon carbide ceramics in high-end fields.

[Progress] In this paper, a comprehensive analysis of the principles behind binder jet 3D printing was provided. The technology utilizes discrete accumulation principles to process physical 3D models by cutting them into 2D cross-sections, which are then gradually deposited and layered through material deposition via computer-controlled programs. Various printing methods were prepared, highlighting the advantages of binder jet 3D printing for the fabrication of silicon carbide (SiC). Subsequently, common challenges, including low density (or high porosity) in printed green bodies, insufficient densification and inadequate strength, were addressed. Current solutions are systematically presented, such as improving green body density through particle grading to enhance printing density. Then, the performances of SiC carbonization achieved via binder jet 3D printing were further evaluated, by analyzing existing researches from universities and manufacturers world widely. A comparative analysis of domestic and international enterprises’ approaches and their performance characteristics in SiC ceramic binder jet 3D printing was conducted. Finally, the application of binder jet 3D printing across multiple industrial fields was reviewed.

[Conclusions and prospects] The fundamental principles underlying binder 3D printing technology was comprehensively reviewed, including powder spreading, selective binder jetting and post-processing techniques (such as melt infiltration and precursor immersion cracking). The key methods to enhance green body density were elaborated, including powder morphology modification, binder optimization and control of printing process parameters. Regarding the challenges in densification of SiC ceramic sintering, the advantages and limitations of existing post-processing technologies were analyzed. It is indicated that, through material and process optimization, high-performance large-sized SiC ceramic components have been successfully fabricated. However, challenges persist in addressing issues, such as excessive binder particle size, insufficient sintered ceramic strength and limited precision. Future development trends should be on advancing high-strength high-precision SiC ceramic binder jetted 3D printing. Key priorities include achieving atmospheric solid-state and liquid-phase sintering of composite materials, integrating AI for intelligent optimization, virtual prototyping and performance prediction in binder jetted 3D printing systems, thereby driving the technology toward advanced industrial applications.

Key words: binder jet 3D printing; silicon carbide ceramics; densification; research status