Stereolithography-based additive manufacturing of polymer-derived SiOC/SiC ceramic composites

Essmeister, Johannes; Altun, Altan Alpay; Staudacher, Maximilian; Schwentenwein, Martin; Konegger, Thomas

doi:10.1016/j.jeurceramsoc.2022.06.021

Cited by 25 publications

(14 citation statements)

References 28 publications

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“…The photocurable preceramic polymer system used in this work is based on a materials system recently established in our team for the development of additively manufactures SiOC/SiC composites ( Essmeister et al, 2022 ). To prepare the preceramic polymer, 40 g methyl-silsesquioxane (Silres-MK, Wacker Industries) were dissolved in 20 g TPM (Tripropyleneglycol-methylether, Sigma Aldrich) at 70°C under constant stirring.…”

Section: Methodsmentioning

confidence: 99%

“…One possibility to produce these materials is the polymer-derived ceramics (hereafter PDC) route, where a silicon-based polymer is converted into a ceramic during a thermal treatment process ( Colombo et al, 2010 ; Lale et al, 2018 ). This approach offers multiple advantages and opens up new possibilities, including: • Versatile chemical compositions due to a broad variety of preceramic polymers ( Colombo et al, 2010 ) • Tailorable material properties such as introduction of hierarchical porosity ( Colombo, 2008 ; Lale et al, 2018 ; Konegger et al, 2021 ), functionalisation of the ceramic with metal centres which can act as catalysts ( Schubert et al, 2017 ; Fu et al, 2018 ; Macedo et al, 2019 ; Kaur et al, 2020 ; Schumacher et al, 2020 ) or introduction of particulate fillers like SiC to ameliorate mechanical and thermal stability ( Essmeister et al, 2022 ) • Photocurable PDC systems offering a high freedom in shaping as they are suitable for stereolithography-based additive manufacturing ( Zanchetta et al, 2016 ; Fu et al, 2018 ; Schmidt and Colombo, 2018 ; Essmeister et al, 2022 ) …”

Section: Introductionmentioning

confidence: 99%

“…• Tailorable material properties such as introduction of hierarchical porosity ( Colombo, 2008 ; Lale et al, 2018 ; Konegger et al, 2021 ), functionalisation of the ceramic with metal centres which can act as catalysts ( Schubert et al, 2017 ; Fu et al, 2018 ; Macedo et al, 2019 ; Kaur et al, 2020 ; Schumacher et al, 2020 ) or introduction of particulate fillers like SiC to ameliorate mechanical and thermal stability ( Essmeister et al, 2022 )…”

Section: Introductionmentioning

confidence: 99%

“…• Photocurable PDC systems offering a high freedom in shaping as they are suitable for stereolithography-based additive manufacturing ( Zanchetta et al, 2016 ; Fu et al, 2018 ; Schmidt and Colombo, 2018 ; Essmeister et al, 2022 )…”

Section: Introductionmentioning

confidence: 99%

“…• Versatile chemical compositions due to a broad variety of preceramic polymers (Colombo et al, 2010) • Tailorable material properties such as introduction of hierarchical porosity (Colombo, 2008;Lale et al, 2018;Konegger et al, 2021), functionalisation of the ceramic with metal centres which can act as catalysts (Schubert et al, 2017;Fu et al, 2018;Macedo et al, 2019;Kaur et al, 2020;Schumacher et al, 2020) or introduction of particulate fillers like SiC to ameliorate mechanical and thermal stability (Essmeister et al, 2022) • Photocurable PDC systems offering a high freedom in shaping as they are suitable for stereolithography-based additive manufacturing (Zanchetta et al, 2016;Fu et al, 2018;Schmidt and Colombo, 2018;Essmeister et al, 2022) One of the versatile possible applications of PDCs is their use as catalyst carrier structures in heterogeneous catalysis (Konegger et al, 2015). Until now, there exist several studies about the preparation of metal-doped PDCs, some of them reporting on the preparation of Ni-containing PDCs with a focus on the application as catalysts for CO 2 hydrogenation (Schubert et al, 2017;Macedo et al, 2019;Kaur et al, 2020;Schumacher et al, 2020).…”

Section: Introductionmentioning

confidence: 99%

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Polymer-derived SiOC as support material for Ni-based catalysts: CO2 methanation performance and effect of support modification with La2O3

et al. 2023

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In this study, we investigated Ni supported on polymer-derived ceramics as a new class of catalyst materials. Catalysts have to withstand harsh reaction conditions requiring the use of a support with outstanding thermal and mechanical stability. Polymer-derived ceramics meet these requirements and bring the additional opportunity to realize complex porous structures. Ni-SiOC and La-modified Ni-SiOC catalysts were prepared by wet impregnation methods with target concentrations of 5 wt% for both metal and oxide content. Polymer-derived SiOC supports were produced using a photoactive methyl-silsesquioxane as preceramic polymer. Catalysts were characterized by N2-adsorption-desorption, XRD, SEM, H2-TPR, and in-situ DRIFTS. CO2 methanation was performed as a test reaction to evaluate the catalytic performance of these new materials at atmospheric pressure in the temperature range between 200°C and 400°C. XDR, H2-TPR, and in-situ DRIFTS results indicate both improved dispersion and stability of Ni sites and increased adsorption capacities for CO2 in La-modified samples. Also, modified catalysts exhibited excellent performance in the CO2 methanation with CO2 conversions up to 88% and methane selectivity >99% at 300°C reaction temperature. Furthermore, the pyrolysis temperature of the support material affected the catalytic properties, the surface area, the stability of active sites, and the hydrophobicity of the surface. Overall, the materials show promising properties for catalytic applications.

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Section: Methodsmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

See 3 more Smart Citations

Polymer-derived SiOC as support material for Ni-based catalysts: CO2 methanation performance and effect of support modification with La2O3

et al. 2023

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Hierarchically Porous Ceramic and Metal‐Ceramic Hybrid Materials Structured by Vat Photopolymerization‐Induced Phase Separation

Essmeister,

Fuchsberger,

Steiner

et al. 2023

Adv Materials Technologies

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Additive manufacturing techniques such as vat photopolymerization have laid the foundation for impressive advances in the 3D structuring of ceramic materials. However, simultaneous structuring of these complex‐shaped ceramic objects on the sub‐µm scale, an essential feature for a wide range of applications in separation, energy conversion and storage, adsorption or sensing, has remained a tremendous challenge. This study demonstrates how complex‐shaped polymer‐derived SiOC ceramics exhibiting hierarchical porosity ranging from the sub‐µm‐ to the millimeter‐range can be generated by combining vat photopolymerization with photopolymerization‐induced phase separation using preceramic polymer‐based phase‐separating resins. In addition to allowing single‐step, multi‐level structural control, this new processing concept allows for the chemical modification of the 3D‐printable, phase‐separating preceramic polymer resins using organometallic compounds, including the possibility to generate functional metal nanoparticles in situ during the polymer‐to‐ceramic conversion. In this manner, a chemical toolbox is provided, facilitating the introduction of Ni, Co, Mo, or La into the hierarchically structured SiOC matrix. The versatile applicability of this new materials design approach is demonstrated by employing complex‐shaped, hierarchically porous monoliths containing in situ generated Ni nanoparticles as heterogeneous catalysts for CO2 methanation, with a profound increase in catalyst performance attained by oxidative post‐treatment of the metal‐ceramic hybrid material.

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Toward High‐Performance Piezoresistive Polymer Derived SiOC Ceramics through Masked Stereolithography 3D Printing with β‐Silicon Carbide Nanopowder Reinforcement

Rahman,

Phani,

Kim

2023

Macromol. Rapid Commun.

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Enhancing the piezoresistivity of polymer‐derived silicon oxycarbide ceramics (SiOCPDC) is of great interest in the advancement of highly sensitive pressure/load sensor technology for use in harsh and extreme working conditions. However, a facile, low cost, and scalable approach to fabricate highly piezoresistive SiOCPDC below 1400 °C still remains a great challenge. Here, the fabrication and enhancement of piezoresistive properties of SiOCPDC reinforced with β‐SiC nanopowders (SiCNP) through masked stereolithography‐based 3D‐printing and subsequent pyrolysis at 1100 °C are demonstrated. The presence of free carbon in SiCNP augments high piezoresistivity in the fabricated SiCNP‐SiOCPDC composites even at lower pyrolysis temperatures. A gauge factor (GF) in the range of 4385–5630 and 6129–8987 with 0.25 and 0.50 wt% of SiCNP, respectively is demonstrated, for an applied pressure range of 0.5–5 MPa at ambient working conditions. The reported GF is significantly higher compared to those of any existing SiOCPDC materials. This rapid and facile fabrication route with significantly enhanced piezoresistive properties makes the 3D‐printed SiCNP‐SiOCPDC composite a promising high‐performance material for the detection of pressure/load in demanding applications. Also, the overall robustness in mechanical properties and load‐bearing capability ensures its long‐term stability and makes it suitable for challenging and severe environment applications.

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Stereolithography-based additive manufacturing of polymer-derived SiOC/SiC ceramic composites

Cited by 25 publications

References 28 publications

Polymer-derived SiOC as support material for Ni-based catalysts: CO2 methanation performance and effect of support modification with La2O3

Polymer-derived SiOC as support material for Ni-based catalysts: CO2 methanation performance and effect of support modification with La2O3

Hierarchically Porous Ceramic and Metal‐Ceramic Hybrid Materials Structured by Vat Photopolymerization‐Induced Phase Separation

Toward High‐Performance Piezoresistive Polymer Derived SiOC Ceramics through Masked Stereolithography 3D Printing with β‐Silicon Carbide Nanopowder Reinforcement

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