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HRL Laboratories, in collaboration with Prodways, has developed fully dense ceramic parts using stereolithography 3D printing

September 22, 2025 Materials 268

The collaboration between HRL Laboratories—a joint research venture of General Motors and Boeing—and additive manufacturing company Prodways is advancing materials science into new frontiers.

technology, the two companies are demonstrating how polymer-derived ceramics can overcome long-standing challenges in 3D printed ceramics.

Unlike traditional powder-based methods, PDCs start as liquid polymers that can first be shaped into complex components before being converted into lightweight, heat-resistant ceramics through high-temperature pyrolysis. This "shape-first" approach avoids many engineering challenges associated with binder burnout and sintering. The technology holds significant potential for industries such as aerospace, energy, and defense, where reliability under extreme conditions is critical.

HRL scientists utilized Prodways' ProMaker L5000 DLP system to produce fully dense silicon oxycarbide ceramics. Experiments revealed that enhanced control is critical: finely dispersed particles increase strength, whereas oversized inclusions introduce microcracks during the polymer-to-ceramic transformation.

This collaboration outlines a development roadmap for producing defect-free, aerospace-grade ceramic components directly from polymer precursors through optimized resin formulations and reinforcement geometries. Beyond demonstrating feasibility, the research establishes a foundation for designing tougher ceramic matrix composites via additive manufacturing.

For HRL and Prodways, this work exemplifies the critical importance of cross-industry collaboration in additive manufacturing: combining advanced research with industrial platforms to transition new materials from lab-scale demonstrations to practical applications.