Disclosed herein are systems and methods for synthesis of polymer derived ceramic materials, including silicon oxycarbide comprising silicon metal. In some embodiments, the silicon metal is formed by carbothermal reduction during thermal processing. In some embodiments, the thermal processing comprises microwave plasma processing. In some embodiments, the silicon metal forms nanodomains within a structure of the silicon oxycarbide ceramic material.

A composite material manufacturing method includes: laminating a first sheet (210) including a first slurry (214) and a third sheet (230) including a third slurry (234); and heating the first sheet (210) and the third sheet (230) that are laminated to a temperature of transforming to ceramics by pyrolysis to form an intermediate body (300). The manufacturing method further includes impregnating the intermediate body (300) with a slurry and heating at a temperature lower than a temperature of transforming to ceramics by pyrolysis.

A composite material manufacturing method includes: laminating a first sheet (210) including a first slurry (214) and a third sheet (230) including a third slurry (234); and heating the first sheet (210) and the third sheet (230) that are laminated to a temperature of transforming to ceramics by pyrolysis to form an intermediate body (300). The manufacturing method further includes impregnating the intermediate body (300) with a slurry and heating at a temperature lower than a temperature of transforming to ceramics by pyrolysis.

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.

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.

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.

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.

A method of making a ceramic matrix composite (CMC) part such as armor, in which a mixture, including a preceramic polymer, particles such as ceramic microparticles and/or nanoparticles, and organic compounds such as a surfactant and a solvent, are mixed to form a paste and printed or molded. The part is then cured and densified by polymer infiltration and pyrolysis (PIP) using the preceramic polymer with a varying amount and size of ceramic particles and different temperatures in some of the cycles. The CMC can contain silicon carbide, boron carbide, boron suboxide, alumina, or any other ceramic. The process is compatible with sacrificial materials, enabling the creation of parts with hollow portions or overhangs. The mixture preferably has a high loading of particles, for example between 70 wt % and 90 wt % of the mixture, in order to minimize shrinkage. Curing and pyrolyzing the part can be performed by microwaving. Two such CMC parts can be joined together by using the paste, having the same or a different concentration of particles, as an adhesive.

A thermally-insulating composite material with co-shrinkage in the form of an insulating material formed by the inclusion of microballoons in a matrix material such that the microballoons and the matrix material exhibit co-shrinkage upon processing. The thermally-insulating composite material can be formed by a variety of microballoon-matrix material combinations such as polymer microballoons in a preceramic matrix material. The matrix materials generally contain fine rigid fillers.

A thermally-insulating composite material with co-shrinkage in the form of an insulating material formed by the inclusion of microballoons in a matrix material such that the microballoons and the matrix material exhibit co-shrinkage upon processing. The thermally-insulating composite material can be formed by a variety of microballoon-matrix material combinations such as polymer microballoons in a preceramic matrix material. The matrix materials generally contain fine rigid fillers.