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February 27, 2026npj Advanced Manufacturing0 citationsOpen Access

Additive manufacturing pathways for polymer-derived ceramics: processing, structure, and function

SKSaurabh KhujeNKNicholas KuABAndres Bujanda

Key Points

  • The review aims to synthesize recent advancements in additive manufacturing of polymer-derived ceramics and their processing pathways.
  • Analyzed preceramic polymer chemistry and the formulation of inks and resins.
  • Examined strategies to reduce shrinkage, cracking, and porosity in manufacturing.
  • Mapped additive manufacturing processes to ISO/ASTM 52900 standards including various techniques like vat photopolymerization and material extrusion.
  • Discussed polymer-to-ceramic transformation mechanisms during pyrolysis and their effects on material properties.
  • Outlined challenges and opportunities for scalable and multifunctional additive manufacturing of polymer-derived ceramics.
  • Highlighted pathways toward ultra-high-temperature-ceramics with specific dimensional and phase control requirements.
  • Introduced emerging 4D printing concepts that allow for dynamic changes in shape or properties during processing.

Abstract

Additive manufacturing (AM) of polymer-derived ceramics (PDCs) offers a chemistry-driven route to architected, high-temperature components that are difficult to realize by conventional powder-based forming and machining. By coupling preceramic polymers (PCPs) with digital design, AM-enabled PDC processing provides control over composition, architecture, and microstructure from the molecular scale upward. This review synthesizes recent progress in PCP chemistry and ink and resin formulation, filler strategies to mitigate shrinkage, cracking, and porosity, and AM pathways mapped to ISO/ASTM 52900, including vat photopolymerization, material extrusion, material jetting, BJ, powder bed fusion, and sheet lamination. Emphasis is placed on polymer-to-ceramic transformation, clarifying the roles of crosslinking, gas evolution, and bond reorganization during pyrolysis, and on how equilibrium and non-equilibrium thermal schedules govern phase evolution and densification. Emerging 4D printing concepts that introduce time-dependent shape or property changes prior to or during ceramization are discussed as extensions of AM-enabled PDC processing. Within this broader framework, pathways toward ultra-high-temperature-ceramic-relevant compositions are highlighted as stringent test cases for dimensional stability and phase control. Finally, the review surveys application spaces and outlines key challenges and opportunities for scalable, multifunctional AM-PDC systems.

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Cite This Study

Khuje et al. (2026) studied this question.

synapsesocial.com/papers/69a134fbed1d949a99abe694https://doi.org/10.1038/s44334-026-00068-x
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