Researchers at the U.S. Department of Energy’s Oak Ridge National Laboratory (ORNL) have developed a new way to 3D print ceramics that could transform industries ranging from pharmaceuticals to aerospace.
Their method solves one of the biggest challenges in ceramic additive manufacturing: creating large, leak-tight components that can handle extreme conditions.
Ceramics are highly valued in advanced engineering because of their strength, stability, and resistance to high temperatures and chemicals.
These qualities make them ideal for harsh environments like chemical reactors, where durability and leak prevention are critical.
But until now, scaling up ceramic 3D printing has been a major obstacle.
Traditional manufacturing can make strong ceramic parts, but it struggles with the complex shapes required for modern reactors. Meanwhile, existing 3D printing methods often fall short in size, sealing ability, or mechanical reliability.
The ORNL team combined a technique called binder jet additive manufacturing (BJAM) with a novel post-processing method to overcome these hurdles.
BJAM works by laying down thin layers of ceramic powder and binding them together with a liquid agent to form solid objects.
It’s cost-effective and efficient, but until recently, it wasn’t capable of producing the large, leak-proof parts needed for industrial applications.
Lead researcher Trevor Aguirre and his colleagues discovered a robust joining strategy that allows smaller ceramic pieces to be 3D printed separately and then fused together into larger, sealed structures.
The result is the first known leak-tight joint created through additive manufacturing. This achievement means that scalable assemblies for high-performance reactors are now within reach.
To ensure success, the researchers tested multiple design approaches to find structures that naturally supported gas-tight performance.
They also developed specialized post-processing treatments to strengthen the bonds between ceramic segments and enhance their sealing ability. These methods not only prevent leaks but also maintain the strength and durability needed for extreme environments.
The implications of this innovation are far-reaching. Chemical reactors, which are critical for producing pharmaceuticals and processing chemicals, could benefit from more efficient, durable, and complex designs.
The new technique also has potential applications in aerospace, where lightweight and heat-resistant materials are essential, and in other industries that rely on high-performance components.
By merging cost-efficient BJAM with advanced sealing techniques, the ORNL team has demonstrated a practical and scalable path forward for ceramic additive manufacturing.
Their work, published in Ceramics International, shows how 3D printing can go beyond small prototypes to create large, functional systems that were previously impossible to build.
“This advancement provides a validated methodology to produce high-quality components—and enable the development of next-generation reactors,” said Aguirre.
With this breakthrough, ceramic 3D printing may soon move from the lab to the heart of some of the world’s most demanding technologies.
Source: Oak Ridge National Laboratory.
