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<p>In this study, porous silicon nitride (Si<sub>3</sub>N<sub>4</sub>) ceramics were innovatively prepared using screw extrusion and particle feedstock-based fused deposition modeling (FDM) technology. The printing properties, degreasing, sintering processes, and typical printing defects of the feedstock were investigated. The results showed excellent printing performance of silicon nitride particles in FDM, suitable for the production of complex parts. A two-step ‘solvent + heat’ degreasing process with an organic binder system was developed, which offers several advantages for the preparation of thick-section parts and safely degreases parts over 20&#xa0;mm thick. Combined with pressure-assisted sintering, the resulting porous silicon nitride ceramics exhibited maximum bending strength (180&#xa0;MPa), elastic modulus (62.1&#xa0;GPa), fracture toughness (2.82&#xa0;MPa&#xa0;m<sup>1/2</sup>), compressive strength (215&#xa0;MPa), and density (2.01&#xa0;g/cm<sup>3</sup>). The electrical and thermal properties of the samples were investigated and showed excellent dielectric performance. Using an impeller as a typical sample, the preparation process was completed, and sintering was achieved. The study identified improper pressure path combinations as common causes of FDM process failures and proposed a novel concept of in situ precursor auto-enhancement and <i>β</i>-phase seed induction to mitigate pore effects on mechanical properties. These research results provide important theoretical and practical guidance for the use of FDM technology in the preparation of porous silicon nitride ceramics with promising engineering applications.</p>

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Performance Study of Porous Silicon Nitride Ceramics Prepared by 3D Printing Based on FDM Technology

  • 期刊论文

  • 发表日期：

    2025年10月27日

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  • Fei Wang,
  • Jian Li,
  • Yingying Wang,
  • Jize Yu,
  • Zhuoqun Han,
  • Ling Li

摘要

In this study, porous silicon nitride (Si3N4) ceramics were innovatively prepared using screw extrusion and particle feedstock-based fused deposition modeling (FDM) technology. The printing properties, degreasing, sintering processes, and typical printing defects of the feedstock were investigated. The results showed excellent printing performance of silicon nitride particles in FDM, suitable for the production of complex parts. A two-step ‘solvent + heat’ degreasing process with an organic binder system was developed, which offers several advantages for the preparation of thick-section parts and safely degreases parts over 20 mm thick. Combined with pressure-assisted sintering, the resulting porous silicon nitride ceramics exhibited maximum bending strength (180 MPa), elastic modulus (62.1 GPa), fracture toughness (2.82 MPa m1/2), compressive strength (215 MPa), and density (2.01 g/cm3). The electrical and thermal properties of the samples were investigated and showed excellent dielectric performance. Using an impeller as a typical sample, the preparation process was completed, and sintering was achieved. The study identified improper pressure path combinations as common causes of FDM process failures and proposed a novel concept of in situ precursor auto-enhancement and β-phase seed induction to mitigate pore effects on mechanical properties. These research results provide important theoretical and practical guidance for the use of FDM technology in the preparation of porous silicon nitride ceramics with promising engineering applications.