DIGITAL LIGHT PROCESSING OF POLYMER-DERIVED CERAMIC PRECURSORS FOR THE FABRICATION OF SILICON OXYCARBIDE COMPOSITES

Ceramic composites are highly desirable for aerospace and extreme environment applications due to their exceptional thermal stability, mechanical strength, and oxidation resistance. Polymer-derived ceramics (PDCs) offer a versatile route to fabricating such composites, with the added advantages of tunable properties—such as electrical and thermal conductivity—and processing at lower temperatures and pressures compared to conventional sintering methods. Their polymeric origin also enables additive manufacturing via vat-based techniques. In this work, SiOC ceramic composites were synthesized from photo-curable polysiloxane precursors and shaped into complex geometries using Digital Light Processing (DLP). Photocurable groups were incorporated into the polymer backbone, enabling UV crosslinking at 405 nm. To tailor composite properties, Silicon Carbide, Hexagonal Boron Nitride, and Alumina were introduced as fillers. The effects of these additives on both printability and final microstructure were evaluated. Pyrolysis at 1000 °C converted the crosslinked structures into ceramics. The resulting composites are expected to exhibit reduced shrinkage, enhanced mechanical properties, thermal stability, and thermal conductivity, making them strong candidates for aerospace applications.