Hypersonic vehicles require highly durable materials, and researchers at the Purdue Applied Research Institute (PARI) are developing new additive manufacturing techniques to 3D print dark ceramics . This material is capable of withstanding extreme conditions in hypersonic flight . This advancement will allow complex components to be manufactured on a large scale, optimizing the efficiency and performance of these high-speed aircraft.
Dark ceramics: resistance and technology
Dark ceramics are notable for their high resistance to extreme temperatures and low propensity to crack or degrade in hypersonic environments. To manufacture these components, the PARI team uses 3D printers at the Hypersonic Advanced Manufacturing Technology Center (HAMTC).
These printers use digital light processing (DLP), a technique that projects ultraviolet light onto layers of slurry composed of ceramic powder and resin, progressively hardening the material.
Applications in hypersonic vehicles
Components made from 3D-printed dark ceramic play an essential role in the evolution of hypersonic vehicles, as they must withstand extreme operating conditions such as temperatures exceeding 2000 degrees Celsius and intense aerodynamic pressures.
Thanks to their highly resistant structure, these ceramics can reduce wear and improve the aerodynamic efficiency of critical components such as missile casings and aircraft heat shields.
Furthermore, their ability to maintain structural integrity during high-speed maneuvers makes them a reliable alternative to traditional materials, offering new opportunities for the development of advanced technologies in the fields of defense and aerospace exploration .
Challenges in 3D printing dark ceramics
One of the main challenges lies in the ability of dark ceramics to absorb UV light, which affects curing depth and manufacturing time. To overcome this obstacle, researchers have been fine-tuning resin properties and applying surface treatments that optimize the interaction of the material with light.
The PARI team is also working on the post-processing phase to prevent structural defects in larger parts, such as delamination and cracking. These advances are essential for the manufacturing of reliable components on an industrial scale.
This project is part of an initiative funded by the Office of the Secretary of Defense’s Manufacturing Science and Technology Program, in collaboration with the Naval Surface Warfare Center and other entities. With these innovations, PARI strengthens the development of hypersonic technologies , consolidating its leadership in advanced materials for aeronautics and defense.
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Source and photo: Purdue Applied Research Institute
