Low-Carbon Manufacturing of Ti-Si-C Ceramics Using Geopolymer-Binder-Integrated Reactive Feedstocks

The ceramic manufacturing sector, recognized as a highly energy-consuming industry, is set to boost energy efficiency and reduce carbon footprint. Here, we present a new self-sustaining ceramization-assisted additive manufacturing (AM) of ceramic composite structures. The eco-friendly process features extrusion-based printing of geopolymer-bonded reactive microparticles, ambient environment curing, and self-sustaining ceramization. Our approach exhibits an extraordinarily low manufacturing carbon footprint with a greenhouse gas (GHG) emission of 0.79 kg of CO₂ equivalent/kg, a 1000-fold decrease compared to standard binder jetting ceramic AM. The resultant structure comprises a Ti-Si-C-based ceramic composite, simultaneously showcasing the lowest open porosity (22%) compared to other reactively 3D-printed inorganic structures. The proposed technology has the potential to pave the way for low-carbon manufacturing of geometrically intricate ceramic composite structures.