Recent Advances in 3D Printing and Densification of SiC Ceramics

SiC ceramics exhibit high strength and thermal stability, rendering them highly suitable for applications in space and thermal components. However, the growing demand for large-sized and complex-shaped SiC ceramics necessitates advanced manufacturing techniques. In comparison to traditional reduction and equal material manufacturing methods, 3D printing technology offers significant advantages in various aspects, such as manufacturing cycle, effective cost, and reliability. There are many 3D printing methods, each with distinct characteristics. Stereolithography (SLA) is capable of achieving high precision and superior surface quality. However, its practical applications often necessitate special design of support structures. Additionally, issues such as residual stress and low solid content significantly hinder its further development. Selective laser sintering (SLS) exhibits strong material compatibility, which is suitable for a wide range of materials, including polymers, metals and ceramics. This technology enables large-scale rapid prototyping at low manufacturing costs. But its surface quality of the formed billet is typically insufficient, which needs additional post-processing. Fused deposition modeling (FDM) though facilitates the preparation of SiC ceramics via reaction sintering, proves unsuitable for constructing large components which restricts its applicability in actual production contexts, due to its inadequate interlayer bonding strength coupled with pronounced surface striations and slower forming speeds. This paper reviews the latest research progresses of 3D-printed SiC ceramics and analyzes the subsequent high-temperature densification treatments of green bodies, along with their fundamental physical properties. Finally, it proposes some prospects of 3D printing of SiC ceramic materials, and strengthens integration of new 3D printing technologies and various printing methods for fine regulation of ceramics' macro-and micro-structures.