HRL Laboratories & Prodways: Ceramic 3D Printing

HRL Laboratories is a world-renowned research center based in Malibu, California. Now jointly owned by General Motors and Boeing, HRL has a long history of breakthrough innovations in materials science, electronics, and aerospace technologies. Their expertise in ceramics and composites makes them a strategic partner for pushing the boundaries of additive manufacturing.

Polymer-derived ceramics (PDCs) : A Materials Revolution

Polymer-derived ceramics (PDCs) are an exciting class of materials that begin as liquid polymers and, through high-temperature pyrolysis, are transformed into advanced ceramics. This unique route allows engineers to shape complex components using 3D printing before converting them into lightweight, heat-resistant, and durable ceramics. PDCs are increasingly important for aerospace, energy, and defense applications where extreme environments demand materials that combine design flexibility with outstanding performance. This unique shaping method allows to alleviate many limitations from conventional AM shaping methods, in particular the binder burn-out and sintering associated engineering challenges.

The Prodways and HRL Collaboration: Advancing the Limits of 3D Printing

HRL Laboratories leveraged Prodways’ high-resolution 3D printing technology to push the boundaries of what PDCs can achieve. Using Prodways’ ProMaker L5000 digital light projection system, HRL scientists used the PDC approach to manufacture fully densified silicon-oxycarbide ceramics. This work demonstrated that precise control over reinforcement size and distribution is key: small particles can strengthen the ceramic without defects, while oversized inclusions may trigger microcracks during conversion.

A Promising Future for High-Performance Ceramics

The findings point to a clear path forward—by optimizing resin formulations and reinforcement geometries, additive manufacturing can deliver tough, defect-free ceramic components directly from polymer precursors. This research not only confirms the feasibility of producing high-performance ceramic matrix composites by 3D printing but also provides fundamental insights to guide future aerospace- and defense-grade applications.

Prodways and HRL are proud to highlight this collaboration as an example of how cutting-edge 3D printing platforms support pioneering materials research, bringing us closer to scalable, next-generation ceramic manufacturing.

Continuing Innovation with Ceram Pro 365

Prodways continues to deliver innovative solutions for advanced ceramic 3D printing. With the latest 3D Printers Ceram Pro 365, designers and engineers can explore new materials, optimize complex geometries, and accelerate the development of high-performance components for aerospace, defense, energy, and beyond.

Discover how Ceram Pro 365 can support your next R&D : Learn more about CERAM PRO 365

References and Key Contributors from HRL

This work builds on the pioneering research conducted by HRL Laboratories, including the following studies:

Additive Manufacturing of Polymer-Derived Ceramic Matrix CompositesMark R. O’Masta, Ekaterina Stonkevitch, Kayleigh A. Porter, Phuong P. Bui, Zak C. Eckel, Tobias A. Schaedler
Reinforcement Induced Microcracking During the Conversion of Polymer-Derived CeramicsMark R. O’Masta, Phuong P. Bui, Natalie M. Larson, Kayleigh A. Porter, Erin S. Wernick, Ekaterina Stonkevitch, Zak C. Eckel, Tobias A. Schaedler

These publications and the contributions of the HRL research team have been instrumental in advancing ceramic 3D printing and demonstrating the potential of additive manufacturing for high-performance applications.

[Case Study] Prodways and HRL Laboratories Advance Ceramic 3D Printing for Next-Generation R&D

Polymer-derived ceramics (PDCs) : A Materials Revolution

The Prodways and HRL Collaboration: Advancing the Limits of 3D Printing

A Promising Future for High-Performance Ceramics

Continuing Innovation with Ceram Pro 365

References and Key Contributors from HRL

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