Sol–Gel Derived Polymer Precursors for Stereolithography of ZrC

Zirconium carbide (ZrC) is a target material for high‐temperature, aerospace, and nuclear shielding applications. However, traditional manufacturing of ZrC components is time and energy intensive and new approaches are needed. A polymer‐derived ceramics method to achieve ZrC‐based components can reduce manufacturing times and promote carbothermal reduction faster than solid‐state reactions. Solution‐based polymeric precursors for ZrC are prepared via a ligand exchange reaction between zirconium(IV) propoxide (Zr(OPr) 4 ) and acrylic acid and printed using a masking stereolithography (MSLA) 3D printer. The polymeric green bodies are pyrolyzed in argon at 1500°C to generate ZrC in situ through carbothermal reduction. Additional polymeric components, trimethylolpropane triacrylate (TMPTA), poly(propylene glycol) (PPG), and poly(ethylene glycol) diacrylate are explored as potential additives to provide mechanical strength to the polymeric green body during printing and pyrolysis. X‐ray diffraction shows that ZrC is the primary crystalline product at high Zr concentrations, but at low concentrations a composite of ZrO 2 and ZrC is favored. The resulting lightweight ceramic lattices ( ρ s = 0.112 − 0.168 g/cm 3 ) have a maximum compressive strength of 0.85 ± 0.23 MPa, similar to other additively manufactured polymer‐derived ceramic lattices. Such solution based polymeric ZrC precursors could pave the way for rapid manufacturing with reduced energy cost.