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Unlocking Ceramic 3D Printing for Next Generation Chemical Reactors
In collaboration with chemical technology and engineering company Dimensional Energy, scientists at the U.S. Department of Energy’s Oak Ridge National Laboratory (ORNL) have integrated binder jet additive manufacturing with an advanced post-processing method to fabricate leak-tight ceramic components, overcoming a key challenge of ceramic additive manufacturing.
While ceramic components perform exceptionally well in extreme environments — exhibiting high temperature resistance, chemical stability and mechanical strength — current methods of ceramic 3D printing fall short on scalability. This shortcoming limits their use in critical applications such as high-throughput chemical reactors, which are used for pharmaceutical or chemical processing, where large, leak-proof parts are essential. ORNL’s innovative solution provides a scalable method for creating complex ceramic structures by leveraging a robust joining technique that enables smaller 3D-printed pieces to be assembled to create the needed components.
ORNL partnered with Dimensional Energy to perform a comprehensive case study. The team evaluated multiple design configurations to pinpoint optimal structures that inherently ensure gas-tight integrity. In addition, the team developed advanced post-processing techniques to improve the bonding and sealing of ceramic segments.
Not only does the innovation help meet the increasing demand for large-scale components, but it also leverages cost-efficient Scient Binder Jet Additive Manufacturing (BJAM), where powder layers are fused with a binder to create solid objects. This method offers substantial economic benefits and paves the way for broader industrial adoption of ceramic additive manufacturing in other high performance applications such as aerospace, among others. This is the first known leak-tight joint fabricated using additive manufacturing methods, paving the way for scalable BJAM assemblies.
www.ornl.gov
