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<p>Although metal–ceramic composites possess high strength, stiffness, and toughness, their engineering applications remain limited owing to multifaceted engineering requirements. Scaffold engineering offers potential for fabricating such composites, yet it often relies on advanced specialized printers. In this study, we present a novel composite engineering strategy for producing copper-alumina (Cu/Al<sub>2</sub>O<sub>3</sub>) metal–ceramic composites by integrating vat photopolymerization 3D printing with pulsed electrodeposition. This process enables efficient copper infiltration into the complex channels of a 3D-printed ceramic scaffold, yielding composites with exceptional mechanical performance. Unlike conventional high-temperature infiltration techniques, our method operates at room temperature, requires no external pressure, and reduces energy consumption by more than 47-fold. The fabricated composite demonstrates remarkable enhancements, including a 24-fold increase in strength and a 64-fold increase in mechanical energy absorption compared to the ceramic preform. These improvements are attributed to the synergistic interaction between the infiltrated metal and the architected ceramic scaffold, as confirmed by micro-computed tomography, digital image correlation, and microstructural analysis. Overall, this approach establishes an energy-efficient pathway for manufacturing high-strength, tough metal–ceramic composites with broad engineering applicability.</p>

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Energy-efficient fabrication of Cu/Al2O3 metal–ceramic composites with enhanced mechanical performance via 3D printing and electrodeposition

  • 期刊论文

  • 发表日期：

    2026年3月5日

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  • Jiarui Yu,
  • Verly Veto Vermol,
  • Salwa Ayob,
  • Wei Zhang,
  • Saddam Hussain

摘要

Although metal–ceramic composites possess high strength, stiffness, and toughness, their engineering applications remain limited owing to multifaceted engineering requirements. Scaffold engineering offers potential for fabricating such composites, yet it often relies on advanced specialized printers. In this study, we present a novel composite engineering strategy for producing copper-alumina (Cu/Al2O3) metal–ceramic composites by integrating vat photopolymerization 3D printing with pulsed electrodeposition. This process enables efficient copper infiltration into the complex channels of a 3D-printed ceramic scaffold, yielding composites with exceptional mechanical performance. Unlike conventional high-temperature infiltration techniques, our method operates at room temperature, requires no external pressure, and reduces energy consumption by more than 47-fold. The fabricated composite demonstrates remarkable enhancements, including a 24-fold increase in strength and a 64-fold increase in mechanical energy absorption compared to the ceramic preform. These improvements are attributed to the synergistic interaction between the infiltrated metal and the architected ceramic scaffold, as confirmed by micro-computed tomography, digital image correlation, and microstructural analysis. Overall, this approach establishes an energy-efficient pathway for manufacturing high-strength, tough metal–ceramic composites with broad engineering applicability.