A method for making a composite material and composite material

The method addresses polymer-based additive manufacturing challenges by synthesizing composite materials within hydrogels or organogels, improving processability and accuracy while reducing shrinkage and porosity, enabling the production of complex structures with customizable compositions and geometries.

WO2025186264A1 Publication Date: 2025-09-11ECOLE POLYTECHNIQUE FEDERALE DE LAUSANNE (EPFL)
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Patent Information

Application Number
PCT/EP2025/055868
Authority / Receiving Office
WO · WO
Patent Type
Applications
Current Assignee / Owner
Priority Date
2024-03-04
Filing Date
2025-03-04
Publication Date
2025-09-11

AI Technical Summary

Technical Problem

Existing polymer-based additive manufacturing processes face challenges in fabricating composites, ceramics, and metals due to high-viscosity resins, homogeneous distribution of ceramic and/or metal particles, light scattering, and material compatibility issues, leading to reduced cure depth, dimensional accuracy, and undesired shrinkage.

Method used

A method involving the synthesis of composite materials by swelling a blank hydrogel or organogel with an inorganic precursor mixture, followed by conversion into ceramic or metal within the gel using reagents and stimuli, allowing for spatial control and reduced shrinkage through multiple cycles and optional thermal treatment.

Benefits of technology

This method enhances processability, accuracy, and resolution by avoiding light scattering and viscosity issues, enabling the production of complex structures with customizable compositions and geometries, reducing shrinkage and porosity, and allowing for higher ceramic or metal loadings.

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Abstract

Herein described is a method for making a composite material, comprising the steps of (a) swelling a blank hydrogel or a blank organogel using an inorganic precursor mixture to form an inorganic precursor-containing solvent-containing gel, wherein the inorganic precursor mixture comprises a solvent and one or more inorganic precursors, and (b) converting the inorganic precursor into ceramic or metal within the solvent-containing gel by introduction of reagents and / or stimuli to obtain a composite material. Optionally, the composite material can be converted into an inorganic material with an additional step (c) comprising thermally treating the composite material. Also described are the resultant composite material and the optional resultant inorganic material.
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