Energy-efficient rapid additive manufacturing of complex geometry ceramics

Energy-intensive industries are one of the key greenhouse gas emitters, and decarbonization of such industries is a top priority to promote global sustainability. As one of the top energy-intensive industries, ceramic manufacturing industries are urged to boost energy efficiency in ceramic structure production. In this paper, we present a rapid and low carbon footprint strategy for freeform manufacturing spatial ceramic composites. Our approach integrates layer-by-layer deposition, photothermal in-situ solidification, and self-sustaining ceramization, enabling consolidation using only 1920 J energy. Compared to state-of-the-art processes, energy consumption can be reduced by over 100-fold, resulting in an estimated 1000-fold decrease in CO2 emissions. This energy-efficient process also demonstrates the rapid fabrication of ceramic gyroid heat exchangers, capable of withstanding extreme environments.