Title: Additive Manufacturing of Complex Silicon Carbide Structures for Hypersonic Applications

Authors: Juno Johnson, Marissa Baker, Thale Smith, Xuan Wang, Eltahry Elghandour

DOI:

Abstract: Ceramic materials, including silicon carbide (SiC), are attractive for many applications due to their high melting temperatures and oxidation resistance. However, integration of ceramic components in designs is often difficult due to the geometric limitations imposed by conventional manufacturing techniques (e.g., slip casting, hot pressing, press and sinter). Binder jetting is an additive manufacturing technique that can manufacture parts with complex geometries including internal cavities and overhangs, from untreated powders. This study evaluates the suitability of binder jetting for the fabrication of geometrically complex SiC components. Binder jetting process parameters were systematically varied to establish processing conditions for SiC material feedstocks, including bimodal powder mixtures. The effects of process parameters, powder mixing, and manufacturing conditions on material characterization were evaluated. Bimodal powder mixtures are expected to enhance packing density, reduce shrinkage rates, and enhance densification of the final parts. By demonstrating the feasibility of binder jetting for SiC, this study provides a pathway toward integrating complex ceramic components for demanding applications.

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Conference: SAMPE 2026

Publication Date: 2026/04/27

SKU: 11

Pages: 14

Price: $28.00