Ceramic-
polymer composites and methods. The
ceramic-
polymer composites, in
powder and / or pellet forms, comprise a plurality of core-shell particles, where: each of the core-shell particles comprises a core and a shell around the core; the core comprises a
ceramic selected from the group of ceramics consisting of: Al2O3 , Fe2O3 , ZnO , ZrO2 , and SiO2 ; and the shell comprises a
polymer selected from the group of polymers consisting of: PC copolymers,
polyetherimide (PEI),
polyetherimide (PEI) copolymers,
polyphenylsulfone (PPSU), polyarylethersulfone (PAES), and polyether sulfones (PES). In
powder form, the core-shell particles are in a substantially
dry powder form having a
moisture content of less than 2% by weight. In pellet form, shells of adjacent core-shell particles are joined to
resist separation of the adjacent core-shell particles and deformation of a respective pellet. Methods of forming a
ceramic-polymer composite comprise:
superheating a mixture of polymer,
solvent, and ceramic, to dissolve the polymer in the
solvent; agitating the superheated mixture while substantially maintaining the mixture at an elevated
temperature and pressure; and cooling the mixture to cause the polymer to precipitate on the particles of the ceramic and thereby form a plurality of the present polymer-ceramic core-shell particles. Methods of molding a part comprise subjecting a
powder of the present polymer-ceramic core-shell particles that substantially fills a mold to a first pressure while the powder is at or above a first temperature above a
melting temperature (Tm) of the polymer.