| Abstract Scope |
Biomineralized systems (e.g., bone and conch shells) exhibit hierarchically porous architecture with excellent mechanical and functional properties. The mainstream biomimetic porous ceramic processing methods, including top-down foaming and bottom-up additive manufacturing, are still constrained in design flexibility as well as multiscale fabrication. To address this, we present a hybrid strategy integrating sacrificial templating and digital light processing (DLP) 3D printing, which enables hierarchically porous ceramic structures with 7-order-of-magnitude feature scaling (from 10-cm-scale dimensions to sub-micron pores), achieving unprecedented multiscale porosity and geometric complexity. We systematically investigated key parameters including slurry formulation, printing strategy, and sintering conditions to optimize printing resolution and microstructural features. Additionally, we demonstrated the feasibility of our strategy for the fabrication of advanced ceramic components, including porous micro-wicks, lightweight lattices, and multiscale bioimplants, providing multifunctional potential in thermal management, mechanical metamaterials, and biomedical devices. |