ORNL scientists crack ceramic 3D printing challenge with leak-tight components, paving way for scalable, high-performance reactors.
Scientists cracks ceramic 3D printing challenge with leak-tight components-74Scientists at the U.S. Department of Energy’s Oak Ridge National Laboratory have achieved a breakthrough in ceramic additive manufacturing.
They combined binder jet additive manufacturing with an advanced post-processing method to create leak-tight ceramic components. The innovation addresses a critical challenge that has limited ceramics in high-performance applications.Ceramic parts are known for their resilience in extreme environments. They withstand high temperatures, resist chemical corrosion, and offer strong mechanical properties.These qualities make them ideal for sectors such as pharmaceuticals, chemical processing, and aerospace.Breaking barriers in ceramicsBut scaling up ceramic 3D printing has been a persistent roadblock. Large, leak-proof components, which are necessary for high-throughput reactors, have been difficult to manufacture with existing methods.The ORNL team developed a joining technique that changes this. Smaller 3D-printed pieces can now be bonded to form larger leak-tight components. This scalable method opens the door for more complex structures that were once out of reach.“Ceramic 3D printing allows fabrication of intricate and high-performance components that are difficult to achieve with traditional manufacturing methods,” said Trevor Aguirre, lead researcher with ORNL’s Extreme Environment Materials Process Group.“This advancement provides a validated methodology to produce high-quality components — and enable the development of next-generation reactors.”The breakthrough was demonstrated with a component printed using binder jet additive manufacturing . It was filled with a silicon-carbide pre-ceramic polymer and heat-treated to form amorphous silicon carbide.Researchers tested multiple design configurations to identify those that best supported gas-tight integrity. They also refined post-processing methods to improve bonding and sealing between ceramic segments.This marks the first known leak-tight joint fabricated using additive manufacturing. It represents a crucial step toward producing large-scale BJAM assemblies for industrial use.From lab to industryThe approach also offers economic advantages. BJAM fuses powder layers with a binder to build solid objects. It is less costly than other ceramic 3D printing methods and supports faster production.By combining this with ORNL’s joining method, industries can consider ceramics for broader high-performance applications, including aerospace and clean energy.The achievement has already gained recognition. ORNL’s research team received SME’s 2025 Dick Aubin Distinguished Paper Award for their contribution to additive manufacturing. They also published related findings in Ceramics International.The project involved multiple researchers, including Dylan Richardson, Corson Cramer, Amy Elliott, and Kashif Nawaz. Funding came from the U.S. Department of Energy’s Advanced Research Projects Agency-Energy and its Solar Energy Technologies Office. Work was conducted at the Manufacturing Demonstration Facility, a DOE-supported site that functions as a national consortium to accelerate U.S. manufacturing innovation.The findings have been published in Ceramics International.
Binder Jet Additive Manufacturing Ceramic 3D Printing High-Performance Ceramics Industrial Reactors Leak-Tight Ceramics Oak Ridge National Laboratory Silicon Carbide
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