Digitally designed, micro-architected carbon- and ceramic-based materials for sustainable systems

The integration of high-resolution polymer 3D printing and pyrolysis techniques demonstrates promise for fabricating high-performance polymer-derived carbon and ceramic micro-architected metamaterials. The ability to digitally design hierarchical carbon and ceramic micro-structures enables enhanced control of properties like electrical conductivity, geometric active material distribution, and thermal management, which are critical for performance. These advanced structures offer unique advantages for demanding applications, such as heterogeneous catalyst supports in electrified flow reactors, electrodes in electrochemical energy storage, and porous cells for thermionic energy conversion in nuclear power generation.

This project will investigate the processing-structure-property relationships of carbon and ceramic micro-structures that govern material behavior while concurrently developing a library of polymer material systems optimized for scalable additive manufacturing. Through advanced characterization, we aim to ensure that these materials meet the stringent requirements of target applications, including inductively heated chemical reactors and electrodes in batteries, electrolyzers, and thermionic energy conversion cells. Ultimately, the tools, materials, and insights developed for carbon and ceramic structure manufacturing will be transitioned toward commercialization via startup deployment partners.