High-Performance Polymer-derived Ceramics in LCD 3D Printing

Abstract

This study demonstrates the fabrication of high-strength, lightweight polymer-derived ceramics (PDCs) using silicon oxycarbide (SiOC)-precursor formulations with liquid crystal display (LCD) vat photopolymerization (VPP) technology. Complex geometries, such as gyroids and stochastic lattices, are successfully 3D-printed and evaluated under varying feature thicknesses and pyrolysis temperatures (800 °C and 1200 °C). Photorheology and thermogravimetric analysis (TGA) validated the efficient curing and pyrolysis characteristics of a printable precursor formulation based on vinyl methoxysiloxane homopolymer (VMM-010), which demonstrated rapid curing, low viscosity, and compatibility with LCD 3D printing, ensuring precise layering and efficient resin removal. Micro-CT scans confirmed its structural integrity and absence of voids, even in relatively thick components (≈3 mm). The VMM-based PDC lattices achieved specific compressive strengths up to 9.4 MPa g⁻¹ cm3, a 50-fold improvement over comparable lattices produced with a high-porosity SiOC PDC, and exceptional high-temperature stability, maintaining structural integrity after 2 h at 1500 °C. Compositional analysis revealed lower free carbon content and improved ceramic phase formation, driving the enhanced mechanical and thermal performance of the VMM-based ceramic. These findings underscore the scalability, reliability, and superior performance of VMM formulations for LCD 3D printing, offering new possibilities for high-performance ceramic applications in aerospace, automotive, and biomedical industries.