Ceramic X.0

High-precision micro-manufacturing of ceramics

Engineered ceramic materials are widespread in various industrial applications due to their unique properties. However, it is difficult if not impossible to produce micron-scale high-precision ceramic components with current manufacturing techniques. The main aim of this project is thus to develop novel micro-manufacturing techniques for high-precision, ceramic components based on polymer-derived ceramics (PDC).

Scope of Research Activities
1. Development of polymer-derived ceramics (PDC) materials suitable for micro-casting
2. Development of processes and devices to ...

Manufacture micro-molds,
Fill preceramic polymers (PCPs) into these micro-molds (micro-casting) and
Transform the material into PDC micro-parts by pyrolysis

3. Characterization of the ceramic micro-parts regarding in vitro biocompatibility as …

Pacemaker electrodes
Dental implants

Key Technical Problems to Solve

Increase the achievable precision of the ceramic micro-parts.
Find ways to overcome current issues in the manufacturing of high precision ceramics due to shrinkage.
Define PDC compositions leading to bright colored implant materials.
Develop a suitable 3D in vitro model and setup with electrical pacing capabilities to study the fibrotic encapsulation of PDC implant materials.

Demonstrators

High precision watch parts
Implantable (e.g. pacemaker) electrodes
Dental implants

Linked Scientific Publications

Borhani, N., E. Kakkava, C. Moser and D. Psaltis (2018). "Learning to see through multimode fibers." Optica 5(8): 960-966.
Griffoni, C., B. Neidhart, K. Yang, F. Groeber-Becker, K. Maniura-Weber, T. Dandekar, H. Walles and M. Rottmar (2021). "In vitro skin culture media influence the viability and inflammatory response of primary macrophages." Scientific Reports 11(1): 7070.
Kakkava, E., M. Romito, D. B. Conkey, D. Loterie, K. M. Stankovic, C. Moser and D. Psaltis (2019). "Selective femtosecond laser ablation via two-photon fluorescence imaging through a multimode fiber." Biomedical Optics Express 10(2): 423-433.
Konstantinou, G., E. Kakkava, L. Hagelüken, P. V. Warriam Sasikumar, J. Wang, M. G. Makowska, G. Blugan, N. Nianias, F. Marone, H. Van Swygenhoven, J. Brugger, D. Psaltis and C. Moser (2020). "Additive micro-manufacturing of crack-free PDCs by two-photon polymerization of a single, low-shrinkage preceramic resin." Additive Manufacturing 35: 101343.
Makowska, M., P. V. W. Sasikumar, L. Hagelüken, D. F. Sanchez, N. Casati, F. Marone, G. Blugan, J. Brugger and H. Van Swygenhoven (2020). "Cracks, porosity and microstructure of Ti modified polymer-derived SiOC revealed by absorption-, XRD- and XRF-contrast 2D and 3D imaging." Acta Materialia 198: 134-144.
Rahmani, B., D. Loterie, G. Konstantinou, D. Psaltis and C. Moser (2018). "Multimode optical fiber transmission with a deep learning network." Light: Science & Applications 7(1): 69.
Teğin, U., E. Kakkava, B. Rahmani, D. Psaltis and C. Moser (2019). "Spatiotemporal self-similar fiber laser." Optica 6(11): 1412-1415.
Vallachira Warriam Sasikumar, P., G. Blugan, N. Casati, E. Kakkava, G. Panusa, D. Psaltis and J. Kuebler (2018). "Polymer derived silicon oxycarbide ceramic monoliths: Microstructure development and associated materials properties." Ceramics International 44(17): 20961-20967.
Vallachira Warriam Sasikumar, P., E. Müller, P. Clement, J. Jang, E. Kakkava, G. Panusa, D. Psaltis, K. Maniura-Weber, M. Rottmar, J. Brugger and G. Blugan (2020). "In Vitro Cytocompatibility Assessment of Ti-Modified, Silicon-oxycarbide-Based, Polymer-Derived, Ceramic-Implantable Electrodes under Pacing Conditions." ACS Applied Materials & Interfaces 12(15): 17244-17253.

Leading Principal Investigator

Prof. Dr. Juergen Brugger
Microsystems Laboratory 1,
EPF Lausanne

Project Consortium

Prof. Dr. Christophe Moser, Laboratory Applied Photonic Devices, EPF Lausanne
Prof. Dr. Demetri Psaltis, Optics Laboratory, EPF Lausanne
Jakob Kübler, Laboratory for High Performance Ceramics, Empa
Dr. Katharina Maniura, Laboratory for Biointerfaces, Empa
Prof. Dr. Helena Van Swygenhoven, Photons for Engineering and Manufacturing Group, PSI