Abstract: This invention provides resin formulations which may be used for 3D printing and pyrolyzing to produce a ceramic matrix composite. The resin formulations contain a solid-phase filler, to provide high thermal stability and mechanical strength (e.g., fracture toughness) in the final ceramic material. The invention provides direct, free-form 3D printing of a preceramic polymer loaded with a solid-phase filler, followed by converting the preceramic polymer to a 3D-printed ceramic matrix composite with potentially complex 3D shapes or in the form of large parts. Other variations provide active solid-phase functional additives as solid-phase fillers, to perform or enhance at least one chemical, physical, mechanical, or electrical function within the ceramic structure as it is being formed as well as in the final structure. Solid-phase functional additives actively improve the final ceramic structure through one or more changes actively induced by the additives during pyrolysis or other thermal treatment.

Abstract: This invention provides resin formulations which may be used for 3D printing and pyrolyzing to produce a ceramic matrix composite. The resin formulations contain a solid-phase filler, to provide high thermal stability and mechanical strength (e.g., fracture toughness) in the final ceramic material. The invention provides direct, free-form 3D printing of a preceramic polymer loaded with a solid-phase filler, followed by converting the preceramic polymer to a 3D-printed ceramic matrix composite with potentially complex 3D shapes or in the form of large parts. Other variations provide active solid-phase functional additives as solid-phase fillers, to perform or enhance at least one chemical, physical, mechanical, or electrical function within the ceramic structure as it is being formed as well as in the final structure. Solid-phase functional additives actively improve the final ceramic structure through one or more changes actively induced by the additives during pyrolysis or other thermal treatment.

Abstract: A system for forming a structural member which includes a first collimated light source and a reservoir containing a volume of photo-monomer resin wherein the first collimated light source is positioned spaced apart from the photo-monomer resin. The system further includes a first face sheet structure defining at least one bore which extends through the first face sheet structure wherein a portion of the first face sheet structure is positioned under a surface of the volume of photo-monomer resin such that photo-monomer resin is positioned within the bore.

Abstract: A sandwich structure configured to be secured with a mechanical fastener includes a core assembly, which includes a polymer component configured for supporting a mechanical fastener connector insert. The core assembly further includes an open cellular component formed from a plurality of self-propagating photopolymer waveguides positioned around the polymer component, wherein a first portion of the plurality of self-propagating photopolymer waveguides is secured to and extends from the polymer component. Further included is a first face sheet secured to a first side of the core assembly, wherein the first portion of the plurality of self-propagating photopolymer waveguides has a distal end spaced apart from the polymer component and secured to the second face sheet.

Abstract: A method for fabricating a ceramic matrix composite structure. A core having an ordered structure is fabricated of a preceramic polymer and pyrolyzed. Facesheets, either uncured or cured, are placed on the core (with a bonding layer of preceramic polymer resin if the facesheets are cured) and the assembly is cured and pyrolyzed. The pyrolyzed assembly is re-infiltrated with preceramic polymer resin and re-pyrolyzed. The cycle of re-infiltration and re-pyrolyzation is repeated until the mass gain per cycle stabilizes.

Abstract: This invention provides resin formulations which may be used for 3D printing and pyrolyzing to produce a ceramic matrix composite. The resin formulations contain a solid-phase filler, to provide high thermal stability and mechanical strength (e.g., fracture toughness) in the final ceramic material. The invention provides direct, free-form 3D printing of a preceramic polymer loaded with a solid-phase filler, followed by converting the preceramic polymer to a 3D-printed ceramic matrix composite with potentially complex 3D shapes or in the form of large parts. Other variations provide active solid-phase functional additives as solid-phase fillers, to perform or enhance at least one chemical, physical, mechanical, or electrical function within the ceramic structure as it is being formed as well as in the final structure. Solid-phase functional additives actively improve the final ceramic structure through one or more changes actively induced by the additives during pyrolysis or other thermal treatment.

Abstract: A sandwich structure configured to be secured with a mechanical fastener includes a core assembly, which includes a polymer component configured for supporting a mechanical fastener connector insert. The core assembly further includes an open cellular component formed from a plurality of self-propagating photopolymer waveguides positioned around the polymer component, wherein a first portion of the plurality of self-propagating photopolymer waveguides is secured to and extends from the polymer component. Further included is a first face sheet secured to a first side of the core assembly, wherein the first portion of the plurality of self-propagating photopolymer waveguides has a distal end spaced apart from the polymer component and secured to the second face sheet.

Abstract: This invention provides resin formulations which may be used for 3D printing and pyrolyzing to produce a ceramic matrix composite. The resin formulations contain a solid-phase filler, to provide high thermal stability and mechanical strength (e.g., fracture toughness) in the final ceramic material. The invention provides direct, free-form 3D printing of a preceramic polymer loaded with a solid-phase filler, followed by converting the preceramic polymer to a 3D-printed ceramic matrix composite with potentially complex 3D shapes or in the form of large parts. Other variations provide active solid-phase functional additives as solid-phase fillers, to perform or enhance at least one chemical, physical, mechanical, or electrical function within the ceramic structure as it is being formed as well as in the final structure. Solid-phase functional additives actively improve the final ceramic structure through one or more changes actively induced by the additives during pyrolysis or other thermal treatment.

Abstract: This invention provides resin formulations which may be used for 3D printing and pyrolyzing to produce a ceramic matrix composite. The resin formulations contain a solid-phase filler, to provide high thermal stability and mechanical strength (e.g., fracture toughness) in the final ceramic material. The invention provides direct, free-form 3D printing of a preceramic polymer loaded with a solid-phase filler, followed by converting the preceramic polymer to a 3D-printed ceramic matrix composite with potentially complex 3D shapes or in the form of large parts. Other variations provide active solid-phase functional additives as solid-phase fillers, to perform or enhance at least one chemical, physical, mechanical, or electrical function within the ceramic structure as it is being formed as well as in the final structure. Solid-phase functional additives actively improve the final ceramic structure through one or more changes actively induced by the additives during pyrolysis or other thermal treatment.

Abstract: A system for forming a structural member which includes a first collimated light source and a reservoir containing a volume of photo-monomer resin wherein the first collimated light source is positioned spaced apart from the photo-monomer resin. The system further includes a first face sheet structure defining at least one bore which extends through the first face sheet structure wherein a portion of the first face sheet structure is positioned under a surface of the volume of photo-monomer resin such that photo-monomer resin is positioned within the bore.