Additively Manufactured Ceramic Lattice-based Interpenetrating Phase Composites: Progress and Challenges

doi:10.15541/jim20250436

Abstract

Abstract:

Interpenetrating phase composites (IPCs), which achieve a continuous interpenetration of porous ceramic skeletons and polymer or metal phases in 3D space, have opened up a new way to overcome the brittleness of ceramics and given new possibilities for the development of next-generation impact-resistant and damage-tolerant advanced ceramics. Additive manufacturing (AM) provides support for the controllable preparation of IPCs. Hence, this paper systematically reviews the progress of additively manufactured ceramic lattice-based IPCs. Firstly, AM processes such as vat photopolymerization, powder bed fusion, material extrusion, and binder jetting are introduced, with their respective technical characteristics and scope of application. Next, ceramic lattice structures, such as honeycomb, truss, plate lattice, and shell structures, are discussed as well as their unique advantages in mechanical properties. Then, core composite processes including infiltration and electrodeposition of two key IPC systems, polymer/ceramic and metal/ceramic IPCs, are provided, and the effects of key parameters such as structural configuration, volume fraction, and gradient design on their mechanical properties are summarized. Finally, based on the current research status, the challenges and opportunities in terms of composite processes, multi-scale structural design, and multifunctional integration are further analyzed and forecasted.

Key words: ceramic lattice structure, interpenetrating phase composite, additive manufacturing, mechanical property, review

CLC Number:

TQ174

YU Feiyu, WANG Wenqing, ZHANG Xueqin, HE Rujie. Additively Manufactured Ceramic Lattice-based Interpenetrating Phase Composites: Progress and Challenges[J]. Journal of Inorganic Materials, 2026, 41(7): 849-866.

Figures/Tables 21

Fig. 1 Interpenetrating phase structures in biomaterials[1-2] (a) Brick and mortar in shell[1]; (b) Bouligand structure in mantis shrimp’s dactyl club[2]

Fig. 2 Commonly used AM technologies for ceramics (a) VPP; (b) PBF; (c) ME; (d) BJ

Fig. 3 Ceramics printed by VPP[7-11] (a) Al2O3 by SLA[7]; (b) Hydroxyapatite (HA) by SLA[8]; (c) Calcium phosphate (CP) by DLP[9]; (d) Tricalcium phosphate (TCP) by DLP[10]; (e) SiOC by TPP[11]

Fig. 4 Ceramics printed by PBF, SLS, ME and BJ[12-17] (a) Si/SiC by PBF[12]; (b) SiC by SLS[13]; (c) ZrB2 by ME[14]; (d) Al2O3 by ME[15]; (e) Al2O3 by BJ[16]; (f) Al2O3 by BJ[17]

Table 1 Summary of AM techniques

AM technique	Layer thickness/μm	Advantage	Disadvantage	Application
VPP	10-25	Extremely high sample quality	Low efficiency	Complex precision parts
PBF	20-60	High sample quality	Prone to defects	High-density parts
ME	100-200	High efficient and low cost	Prone to porosity	Lightweight structural ceramics
BJ	50-100	High efficiency and wide applicability	Poor sample quality	Large size parts

Fig. 5 Mechanical properties of Al2O3 honeycombs[20] (a) Section of the honeycomb; (b) Schematic illustration of the twist angle; (c) Effect of torsion angle on specific compressive strength of honeycomb structures with different wall thicknesses

Fig. 6 Common truss structures[7,21 -23] (a) SC, BCC and FCC[21]; (b) OCT[22]; (c) Porous irregular truss[23]; (d) Graded truss[7]

Fig. 7 Structure parameters of truss[24-26] (a) Lattices with different structural configurations (left) and their load-displacement curves (right)[24]; (b) Lattices with different volume fractions and tilt angles[25]; (c) Gradient lattices with different numbers of cells[26]

Fig. 8 Truncated octahedral plate lattice[28] (a) Schematic diagrams of plate lattice design and unit cell size; (b) Ceramic samples

Fig. 9 Structural parameters and design strategies of TPMS[29-30,32] (a) Common configurations of TPMS[29]; (b) TPMS with different structural configurations and volume fractions[30]; (c) Design strategies for hybrid TPMS[32]

Fig. 10 Mechanical properties of polymer/ceramic IPCs[44-46] (a) Nacre-inspired ceramic scaffold[44]; (b) IPC inspired by trabecular bone and its mechanical properties[45]; (c) Stress-strain curves of single-phase components and IPC[46]; (d) Comparison of compressive strength and energy absorption of single-phase compositions and IPC[46]

Fig. 11 Structural configuration and mechanical properties of polymer/ceramic IPCs[43,47 -48] (a) Trusses and IPCs with different spatial configurations[47]; (b) IPCs of periodic/random shell structures[43]; (c) IPCs of the same truss type[48]; (d) Stress-strain curves of IPCs of the same truss type[48]

Fig. 12 Polymer/ceramic IPCs with different volume fractions[49-50] (a) 20%-40% (in volume) phenol-formaldehyde (PF)/Al2O3 IPCs[49]; (b) 44%-68% (in volume) epoxy resin/ZrO2 IPCs[50]

Fig. 13 Gradient designed polymer/ceramic IPCs[54-55] (a) Macro-morphologies of IPCs and cross section of gradient structure[54]; (b) IPCs of biomimetic gradient Bouligand structures[55]

Fig. 14 Pressureless/pressure assisted infiltration[56,58 -60] (a) Pressureless infiltration[56]; (b) Metal/ceramic IPCs by pressureless infiltration[56]; (c) Pressure assisted infiltration[58]; (d) Metal/ceramic IPCs by pressure assisted infiltration[59-60]

Fig. 15 Mechanical properties of metal/ceramic IPCs[64] (a) Macroscopic morphologies of ceramic lattices and metal/ceramic IPCs; (b) Stress-strain curves of ceramic lattices; (c) Stress-strain curves of metal/ceramic IPCs

Fig. 16 Metal/ceramic IPCs with different structural configurations[66-67] (a) Metal/ceramic IPCs with gyroid and spinodal structures[66]; (b) Metal/ceramic IPCs with BCC and gyroid structures[67]

Fig. 17 Metal/ceramic IPCs with different volume fractions[68,70] (a) Design of gyroid scaffold with different volume fractions[68]; (b) Macroscopic morphologies of Al/Al2O3 IPCs[70]; (c) Compressive strength and flexural strength of Al/Al2O3 IPCs under different volume fractions[70]

Fig. 18 Gradient designed metal/ceramic IPCs[71-72] (a) Gradient volume fraction[71]; (b) Schematic image of Al/Al2O3-B4C green bodies with compositional gradients[72]; (c) Gradient pitch ceramic scaffold[72]; (d) Three-point bending stress-strain curves along the y and z axis directions respectively[72]

Table 2 Comparison of mechanical properties of polymer/ceramic and metal/ceramic IPCs

Type	Composition	Compressive strength/ MPa	Specific energy absorption/ (J·g^-1)	Ref.
Polymer/ ceramic IPCs	Polyurea/Al₂O₃	14.79	2.97	[39]
	Epoxy resin/Al₂O₃	135.00	18.00	[43]
	Polyurea/Al₂O₃	61.03	6.85	[45]
	Resin/Al₂O₃	40.01	17.30	[46]
	Epoxy resin/Al₂O₃	453.30	12.00	[47]
	Phenolic/Al₂O₃	101.09	2.70	[49]
	Phenolic/Al₂O₃	114.86	2.73	[54]
Metal/ ceramic IPCs	Al/ZTA	517.40	13.00	[56]
	Al-Si/ZrO₂	343.00	1.66	[59]
	Al/Al₂O₃	89.01	0.96	[64]
	Al/Al₂O₃	240.00	0.71	[67]
	Al/Al₂O₃	176.10	1.61	[71]

Fig. 19 Algorithm-assisted lattice optimization design process[77]

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