Preview

Proceedings of the National Academy of Sciences of Belarus. Physical-technical series

Advanced search

Analysis of existing methods and additive technologies of 3D printing with polymer-ceramic materials

https://doi.org/10.29235/1561-8358-2026-71-1-7-17

Abstract

This article presents a comprehensive analysis of additive 3D printing technologies using polymer-ceramic composites (PCCs). Particular attention is paid to the advantages, limitations, and prospects of these materials use in medi­ cine, aerospace, and electronics. Additive manufacturing methods applicable to PCCs are systematized, including fused deposition modeling (FDM), stereolithography (SLA), and lithography-based ceramic molding (LCM). A detailed review of commercial and experimental compositions is presented, along with optimal filler content ranges, printing parameters, and post-processing modes. Comparative data demonstrate that the introduction of ceramic additives improves mechanical strength, thermal stability, and functional properties, but is accompanied by technological challenges such as increased material viscosity, abrasive nozzle wear, and shrinkage during sintering. An analysis of current industrial implementations confirms the growing potential of PCCs for biomedicine, energy, and high-tech industries. Polymer-ceramic composites produced using additive manufacturing methods offer a unique combination of polymer processability and ceramic performance. Despite technological challenges, advances in material formulation, equipment design, and digital integration are rapidly expanding the scope of PCC applications. Further optimization of formulations, printing parameters, and hybrid manufacturing methods will accelerate the transition of polymer-ceramic 3D printing from laboratory research to large-scale industrial use.

About the Authors

A. Ph. Ilyushchanka
State Scientific Institution “O. V. Roman Powder Metallurgy Institute”
Russian Federation

Aliaksandr Ph. Ilyushchanka – Academician of the National Academy of Sciences of Belarus, Dr. Sci. (Engineering), Professor, General Director of the State Scientific and Production Association of Powder Metallurgy – Director of the State Scientific Institution “O. V. Roman Powder Metallurgy Institute” 

41, Platonov St., 220005, Minsk 



A. I. Letsko
State Scientific Institution “O. V. Roman Powder Metallurgy Institute”
Russian Federation

Andrey I. Letsko – Cand. Sci. (Engineering), Associate Professor, Head of the Laboratory New Materials and Technologies  

41, Platonov St., 220005, Minsk 



O. O. Kuznechik
State Scientific Institution “O. V. Roman Powder Metallurgy Institute”
Russian Federation

Oleg O. Kuznechik – Head of the Additive Technologies Group of the New Materials and Technologies Laboratory 

41, Platonov St., 220005, Minsk 



M. M. Parnitski
State Scientific Institution “O. V. Roman Powder Metallurgy Institute”
Russian Federation

Mikalai M. Parnitski – Cand. Sci. (Engineering), Senior Researcher of the New Materials and Technologies Laboratory 

41, Platonov St., 220005, Minsk 



Yu. A. Reutsionak
State Scientific Institution “O. V. Roman Powder Metallurgy Institute”
Russian Federation

Yury A. Reutsionak – Head of the SHS-technology group of the New Materials and Technologies 

41, Platonov St., 220005, Minsk 



T. A. Nikalaіchuk
State Scientific Institution “O. V. Roman Powder Metallurgy Institute”
Russian Federation

Tsimafei A. Nikalaіchuk – Postgraduate Student, Junior Researcher of the New Materials and Technologies Laboratory 

41, Platonov St., 220005, Minsk 



References

1. Pereira T., Kennedy J. V., Potgieter J. A. A comparison of traditional manufacturing vs additive manufacturing, the best method for the job. Procedia Manufacturing, 2019, vol. 30, pp. 11–18. https://doi.org/10.1016/j.promfg.2019.02.003

2. Attaran M. The rise of 3-D printing: The advantages of additive manufacturing over traditional manufacturing. Business Horizons, 2017, vol. 60, iss. 5, pp. 677–688. https://doi.org/10.1016/j.bushor.2017.05.011

3. Bhatia A., Sehgal A. K. Additive manufacturing materials, methods and applications: A review. Materials Today: Proceedings, 2023, vol. 81, part 2, pp. 1060–1067. https://doi.org/10.1016/j.matpr.2021.04.379

4. Gao W., Zhang Y., Ramanujan D., Ramani K., Chen Y., Williams C. B., Wang C. C. L. [et al.]. The status, challenges, and future of additive manufacturing in engineering. Computer‑Aided Design, 2015, vol. 69, pp. 65–89. https://doi.org/10.1016/j.cad.2015.04.001

5. Kanishka K., Acherjee B. Revolutionising manufacturing: A comprehensive overview of additive manufacturing processes, materials, developments, and challenges. Journal of Manufacturing Processes, 2023, vol. 107, pp. 574–619. https://doi.org/10.1016/j.jmapro.2023.10.024

6. Fu H., Xu H., Liu Y., Yang Z., Kormakov S., Wu D., Sun J. Overview of injection moulding technology for processing polymers and their composites. ES Materials & Manufacturing, 2020, vol. 8, pp. 3–23. https://doi.org/10.30919/esmm5f713

7. John L. K., Ramu M., Singamneni S., Binudas N. Strength evaluation of polymer ceramic composites: a comparative study between injection molding and fused filament fabrication techniques. Progress in Additive Manufacturing, 2025, vol. 10, pp. 339–347. https://doi.org/10.1007/s40964-024-00626-9

8. Alizadeh-Osgouei M., Li Y., Wen C. A comprehensive review of biodegradable synthetic polymer-ceramic composites and their manufacture for biomedical applications. Bioactive Materials, 2019, vol. 4, pp. 22–36. https://doi.org/10.1016/j.bioactmat.2018.11.003

9. Petousis M., Vidakis N., Mountakis N., Papadakis V., Tzounis L. Three-dimensional printed PA12 and PLA alumina (Al2O3) nanocomposites with significantly enhanced tensile, flexural and impact properties. Nanomaterials, 2022, vol. 12, iss. 23, art. ID 4292. https://doi.org/10.3390/nano12234292

10. Kumar R., Singh R., Hashmi M. S. J. Polymer-ceramic composites: a state of art review and future applications. Advances in Materials and Processing Technologies, 2020, vol. 8, iss. 1, pp. 1–14. https://doi.org/10.1080/2374068X.2020.1835013

11. Travitzky N., Bonet A., Dermeik B., Fey T., Filbert-Demut I., Schlier L., Schlordt T., Greil P. Additive manufacturing of ceramic-based materials. Advanced Engineering Materials, 2014, vol. 16, iss. 6, pp. 729–754. https://doi.org/10.1002/adem.201400097

12. Feilden E., Ferraro C., Zhang Q., Tuñón E. G. 3D printing bioinspired ceramic composite. Scientific Reports, 2017, vol. 7, art. ID 13759. https://doi.org/10.1038/s41598-017-14236-9

13. Vaiani L., Boccaccio A., Uva A. E., Palumbo G., Piccininni A., Guglielmi P., Cantore S. [et al.]. Ceramic materials for biomedical applications: an overview on properties and fabrication processes. Journal of Functional Biomaterials, 2023, vol. 14, iss. 3, art. ID 146. https://doi.org/10.3390/jfb14030146

14. Gopsill J. A., Shindler J., Hicks B. J. Using finite element analysis to influence the infill design of fused deposition modelled parts. Progress in Additive Manufacturing, 2018, vol. 3, pp. 145–163. https://doi.org/10.1007/s40964-017-0034-y

15. Colella R., Chietera F. P., Montagna F., Greco A., Catarinucci L. Customising 3D printing for electromagnetics to design enhanced RFID antennas. IEEE Journal of Radio Frequency Identification, 2020, vol. 4, iss. 4, pp. 452–460. https://doi.org/10.1109/JRFID.2020.3001043

16. Li W. D., Wang C., Yin H. Y., Deng J. B., Mu H. B., Zhang G. J., Chen Y., Song F. L., Chen Y. L. Additive manufacturing of polymer-matrix composite dielectric materials using stereolithography technique. 2021 International Conference on Electrical Materials and Power Equipment (ICEMPE). IEEE, 2021, pp. 1–4. https://doi.org/10.1109/ICEMPE51623.2021.9509221

17. Smirnov A., Seleznev A., Peretyagin P., Bentseva E., Pristinskiy Y., Kuznetsova E., Grigoriev S. Rheological characterization and printability of polylactide (PLA)–alumina (Al2O3) filaments for fused deposition modelling (FDM). Materials, 2022, vol. 15, iss. 23, art. ID 8399. https://doi.org/10.3390/ma15238399

18. Liu W., Wu N., Pochiraju K. Shape recovery characteristics of SiC/C/PLA composite filaments and 3D printed parts. Composites. Part A: Applied Science and Manufacturing, 2018, vol. 108, pp. 1–11. https://doi.org/10.1016/j.compositesa.2018.02.017

19. Fournier S., Chevalier J., Reveron H., Chèvremont W., Baeza G. P. Rheology and structure of ceramic stereolithography slurries: role of powder nature, dispersant and orthogonal strain. Journal of the American Ceramic Society, 2024, vol. 108, iss. 4, art. ID e20304. https://doi.org/10.1111/jace.20304

20. Fu S.-Y., Feng X.-Q., Lauke B., Mai Y.-W. Effects of particle size, particle/matrix interface adhesion and particle loading on mechanical properties of particulate-polymer composites. Composites. Part B: Engineering, 2008, vol. 39, iss. 6, pp. 933–961. https://doi.org/10.1016/j.compositesb.2008.01.002

21. Danilova S. N., Yarusova S. B., Lazareva N. N., Buravlev I. Y., Shichalin O. O., Papynov E. K., Zhevtun I. G. [et al.]. A study of the wear mechanism of composites modified with silicate filler. Ceramics, 2022, vol. 5, iss. 4, pp. 731–747. https://doi.org/10.3390/ceramics5040053

22. Mahmood A., Perveen F., Chen S., Akram T., Irfan A. Polymer composites in 3D/4D printing: materials, advances and prospects. Molecules, 2024, vol. 29, iss. 2, art. ID 319. https://doi.org/10.3390/molecules29020319

23. Gibson J., Rosen D., Stucker B. Additive Manufacturing Technologies. New York, Springer New York, 2015. 498 p. https://doi.org/10.1007/978-1-4939-2113-3

24. Zhao D., Bi G., Chen J., Quach W., Feng R., Salminen A., Niu F. A critical review of direct laser additive manufacturing ceramics. International Journal of Minerals, Metallurgy, and Materials, 2024, vol. 31, pp. 2607–2626. https://doi.org/10.1007/s12613-024-2960-2

25. Fiume E., Coppola B., Montanaro L., Palmero P. Vat-photopolymerization of ceramic materials: exploring current applications in advanced multidisciplinary fields. Frontiers in Materials, 2023, vol. 10, art. ID 1242480. https://doi.org/10.3389/fmats.2023.1242480

26. Bertsch A., Zissi S., Jezequel J., Corbel S. Microstereophotolithography using a liquid crystal display as dynamic mask generator. Microsystem Technologies, 1997, vol. 3, pp. 42–47. https://doi.org/10.1007/s005420050053

27. Vaezi M., Seitz H., Yang S. A review on 3D micro-additive manufacturing technologies. International Journal of Advanced Manufacturing Technology, 2013, vol. 67, pp. 1721–1754. https://doi.org/10.1007/s00170-012-4605-2

28. Zocca A., Colombo P., Gomes C.M., Günster J. Additive manufacturing of ceramics: issues, potentialities and opportunities. Journal of the American Ceramic Society, 2015, vol. 98, iss. 7, pp. 1983–2001. https://doi.org/10.1111/jace.13700

29. Schwentenwein M., Homa J. Additive manufacturing of dense alumina ceramics. International Journal of Applied Ceramic Technology, 2015, vol. 12, iss. 1, pp. 1–7. https://doi.org/10.1111/ijac.12319

30. Sotov A. V., Zaytsev A. I., Abdrahmanova A. E., Popovich A. A. Additive manufacturing of continuous fibre reinforced polymer composites using industrial robots: A review. Izvestiya vuzov. Poroshkovaya metallurgiya i funkcional’nye pokrytiya = Powder Metallurgy and Functional Coatings, 2024, vol. 18, no. 1, pp. 20–30 (in Russian). https://doi.org/10.17073/1997-308X-2024-1-20-30

31. Helou M., Kara S. Design, analysis and manufacturing of lattice structures: an overview. International Journal of Computer Integrated Manufacturing, 2018, vol. 31, iss. 3, pp. 243–261. https://doi.org/10.1080/0951192X.2017.1407456

32. Czepiel M., Bańkosz M., Sobczak-Kupiec A. Advanced injection moulding methods. Materials, 2023, vol. 16, iss. 17, art. ID 5802. https://doi.org/10.3390/ma16175802

33. Chaudhary R. P., Parameswaran C., Idrees M., Rasaki A. S., Liu C., Colombo P. Additive manufacturing of polymer-derived ceramics: materials, technologies, properties and potential applications. Progress in Materials Science, 2022, vol. 128, art. ID 100969. https://doi.org/10.1016/j.pmatsci.2022.100969

34. Smirnov A., Terekhina S., Tarasova T., Hattali L., Grigoriev S. From the development of low-cost filament to 3D printing ceramic parts obtained by fused filament fabrication. The International Journal of Advanced Manufacturing Technology, 2023, vol. 128, pp. 511–529. https://doi.org/10.1007/s00170-023-11849-5

35. Ratnavel R., Viswanath S., Subramanian J., Selvaraj V. K., Prahasam V., Siddharth S. Predicting the optimal input parameters for the desired print quality using machine learning. Micromachines, 2022, vol. 13, iss. 12, art. ID 2231. https://doi.org/10.3390/mi13122231

36. Weng Z., Wang J., Senthil T., Wu L. Mechanical and thermal properties of ABS/montmorillonite nanocomposites for fused deposition modelling 3D printing. Materials & Design, 2016, vol. 102, pp. 276–283. https://doi.org/10.1016/j.matdes.2016.04.045

37. Lalegani Dezaki M., Mohd Ariffin M. K. A., Hatami S. An overview of fused deposition modelling (FDM): research, development and process optimisation. Rapid Prototyping Journal, 2021, vol. 27, iss. 3, pp. 562–582. https://doi.org/10.1108/RPJ-08-2019-0230.

38. Kantaros A., Soulis E., Petrescu F. I. T., Ganetsos T. Advanced composite materials utilised in FDM/FFF 3D-printing manufacturing processes: the case of filled filaments. Materials, 2023, vol. 16, iss. 18, art. ID 6210. https://doi.org/10.3390/ma16186210

39. Wickramasinghe S., Do T., Tran P. FDM-based 3D printing of polymer and associated composite: a review on mechanical properties, defects and treatments. Polymers, 2020, vol. 12, iss. 7, art. ID 1529. https://doi.org/10.3390/polym12071529

40. Li C., Feng C., Zhang L., Wang L. Direct ink writing of polymer‑based materials – A review. Polymer Engineering & Science, 2024, vol. 65, iss. 2, pp. 431–454. https://doi.org/10.1002/pen.27038

41. Sun C., Fang N. X., Wu D. M., Zhang X. Projection micro-stereolithography using digital micro-mirror dynamic mask. Sensors and Actuators A: Physical, 2005, vol. 121, iss. 1, pp. 113–120. https://doi.org/10.1016/j.sna.2004.12.011

42. Skorda S., Bardakas A., Segkos A., Chouchoumi N., Hourdakis E., Vekinis G., Tsamis C. Influence of SiC doping on the mechanical, electrical, and optical properties of 3D-printed PLA. Journal of Composites Science, 2024, vol. 8, iss. 3, art. ID 79. https://doi.org/10.3390/jcs8030079

43. Valerga A.P., Batista M., Salguero J., Girot F. Influence of PLA filament conditions on characteristics of FDM parts. Materials, 2018, vol. 11, iss. 8, art. ID 1322. http://doi.org/10.3390/ma11081322

44. Samykano M., Selvamani S. K., Kadirgama K., Ngui W. K., Kanagaraj G., Sudhakar K. Mechanical property of FDM-printed ABS: influence of printing parameters. The International Journal of Advanced Manufacturing Technology, 2019, vol. 102, pp. 2779–2796. https://doi.org/10.1007/s00170-019-03313-0

45. Rodríguez-Panes A., Claver J., Camacho A. M. The influence of manufacturing parameters on the mechanical behavior of PLA and ABS pieces manufactured by FDM: A comparative analysis. Materials, 2018, vol. 11, iss. 8, art. ID 1333. http://doi.org/10.3390/ma11081333

46. Hwang S., Reyes E. I., Moon K.-S., Rumpf R. C., Kim N. S. Thermo-mechanical Characterization of Metal/Polymer Composite Filaments and Printing Parameter Study for Fused Deposition Modeling in the 3D Printing Process. Journal of Electronic Materials, 2014, vol. 44, pp. 771–777. https://doi.org/10.1007/s11664-014-3425-6

47. Yu G., Ma J., Li J., Wu J. Yu J., Wang X. Mechanical and Tribological Properties of 3D Printed Polyamide 12 and SiC/PA12 Composite by Selective Laser Sintering. Polymers, 2022, vol. 14, iss. 11, art. ID 2167. https://doi.org/10.3390/polym14112167

48. Seenath A. A., Baig M. M. A., Katiyar J. K., Mohammed A. S. A Comprehensive Review on the Tribological Evaluation of Polyether-Ether-Ketone Pristine and Composite Coatings. Polymers, 2024, vol. 16, iss. 21, art. ID 2994. https://doi.org/10.3390/polym16212994

49. Rodzeń A., Sharma P. K., McIlhagger A., Mokhtari M., Dave F., Tormey D., Sherlock R. [et al.]. The Direct 3D Printing of Functional PEEK/Hydroxyapatite Composites via a fused filament fabrication approach. Polymers, 2021, vol. 13, iss. 4, art. ID 545. https://doi.org/10.3390/polym13040545

50. Hidalgo-Carvajal D., Muñoz A. H., Garrido-González J. J., Carrasco-Gallego R. Recycled PLA for 3D printing: a comparison of recycled PLA filaments from waste of different origins after repeated cycles of extrusion. Polymers, 2023, vol. 15, iss. 17, art. ID 3651. https://doi.org/10.3390/polym15173651

51. Pelanconi M., Colombo P., Ortona A. Additive manufacturing of silicon carbide by selective laser sintering of PA12 powders and polymer infiltration and pyrolysis. Journal of the European Ceramic Society, 2021, vol. 41, iss. 10, pp. 5056–5065. https://doi.org/10.1016/j.jeurceramsoc.2021.04.014


Review

Views: 161

JATS XML


Creative Commons License
This work is licensed under a Creative Commons Attribution 4.0 License.


ISSN 1561-8358 (Print)
ISSN 2524-244X (Online)