Ceramic foams through 3D-printed templates @Adv. Eng. Mater.!

In this paper, powder-based three-dimensional (3D) printing was combined with sacrificial templating to realize highly porous yttria-stabilized ZrO2 (YSZ) ceramic foam objects with well-defined geometries. The porous sacrificial template is 3D-printed using poly(methyl methacrylate) powder. Various methods are evaluated to optimize ceramic slurry infiltration into the 3D-printed template and subsequent burn-out. The optimized method yields ceramic foam objects with an open porosity of > 66% and replicates the geometry of the 3D-printed template with high fidelity.

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