Leak-proof ceramic 3D printing paves way for next-gen reactors

Scientists at Oak Ridge National Laboratory (ORNL) have made a significant breakthrough in ceramic additive manufacturing by developing a method to produce leak-tight ceramic components using binder jet additive manufacturing (BJAM) combined with advanced post-processing. This innovation overcomes a major hurdle in scaling ceramic 3D printing for high-performance applications, enabling the creation of larger, complex, and gas-tight ceramic parts that were previously difficult to manufacture. The team demonstrated this by printing components filled with a silicon-carbide pre-ceramic polymer and heat-treating them to form amorphous silicon carbide, achieving the first known leak-tight joint fabricated via additive manufacturing. This advancement not only enhances the fabrication of intricate, resilient ceramic parts ideal for extreme environments—such as those found in pharmaceuticals, chemical processing, aerospace, and clean energy—but also offers economic benefits. BJAM is a cost-effective, faster method compared to other ceramic 3D printing techniques, and ORNL’s joining method allows industries to consider ceramics for broader high-performance