Session Sheet - 2026 Annual International Solid Freeform Fabrication Symposium (SFF Symp 2026): Materials: Ceramics, Glasses

2026 Annual International Solid Freeform Fabrication Symposium (SFF Symp 2026): Materials: Ceramics, Glasses
Program Organizers: David Leigh, University of Texas at Austin

Tuesday 1:30 PM
August 4, 2026
Room: Guadalupe
Location: AT&T Center

1:30 PM
Parametric Evaluation of Scaled Robocasted Alumina Architectures Under Controlled Processing Conditions: Abigail Ortega¹; Jesus Acosta Torres¹; Carmen Rocha¹; Francisco Medina¹; ¹University of Texas El Paso
    Robocasting of ceramics enables fabrication of complex geometries; however, scaling printed structures while maintaining dimensional accuracy and geometric fidelity remains challenging. This study investigates the scale-up behavior of alumina-based ceramic components fabricated using a ceramic slurry maintained at a high solid loading of 55 vol% and identical sintering conditions. Various geometries, including lattices, thin walls, hollow domes, and tall structures, are evaluated to determine the influence of processing conditions on print quality and structural stability. Key printing parameters, including flow rate, print speed, and environmental humidity, are systematically varied under high and low conditions. After sintering, samples are characterized based on shrinkage behavior, dimensional deviation, and overall fidelity to the intended geometry. The objective of this work is to identify processing conditions that enable reliable scaling of robocasted ceramic parts while minimizing distortion and loss of dimensional accuracy in material extrusion additive manufacturing.

1:50 PM
Progress in Additive Manufacturing of Electrode and Electrolyte Materials for Sodium-Ion Energy Storage: Athanasios Goulas¹; Sina Saremi-Yarahmadi¹; Bala Vaidhyanathan¹; ¹Loughborough University
    Additive manufacturing offers a route towards the fabrication of geometrically complex ceramic battery components that cannot be achieved through conventional processing methods. This work presents recent progress in the Digital Light Processing (DLP) additive manufacture of sodium-beta-alumina solid electrolytes and sodium titanate-based anode materials for sodium-ion energy storage. High solids-loading photocurable ceramic suspensions were developed and optimised to achieve the rheological behaviour, dispersion stability, and curing response required for vat photopolymerisation. The work focuses on suspension formulation, printability, thermal processing, and phase stability following sintering. Particular attention is given to the processing challenges associated with sodium-based ceramics, including light scattering effects, suspension stability, and densification behaviour. The work demonstrates the potential of DLP as a manufacturing route for architected sodium-ion battery materials and future all-solid-state ceramic energy storage systems.

2:10 PM
Evaluation of Slurry Sedimentation and Degradation in Aged Commercial Ceramic Slurries: Alex Stevens¹; Juliette Welch¹; Nellie Pestian¹; Pandora Picariello¹; Joy Gockel¹; ¹Colorado School of Mines
     Vat Photopolymerization (VPP) manufacturing of ceramic parts relies on thepolymer suspension of ceramic particles in a loaded slurry. As they age, ceramic slurries are susceptible to particle agglomeration, sedimentation, and oxidative photopolymer degradation. To characterize the degradation and evaluate the usability of expired slurries, this study investigates the usability of expired LithaLox HP500 alumina slurry with expiration dates from 2019, 2023, and 2025. Slurries were homogenized via roller milling, and analyzed via pycnometry, rheology, and a cure depth analysis to measure the viscosity and printability of expired slurries against a 2026 control batch to establish a performance baseline. The study aims to assess, based on the measured properties, whether expired slurries are still viable

2:30 PM
Optimizing Cure Depth Measurements for Ceramic Vat Photopolymerization Industrial Applications: Nellie Pestian¹; Juliette Welch¹; Alex Stephens¹; Joy Gockel¹; ¹Colorado School of Mines
    Cure depth measurements have great potential for rapid process optimization and incoming material qualification in the ceramic vat photopolymerization industry. However, lack of consistency in cure depth measurements between and among labs in academia and industry poses a barrier to technology transfer and standardization. A highly consistent process is required to ensure that small differences in cure depth can be resolved with statistical confidence from the fewest possible number of measurements. This presentation details an approach for optimizing the efficiency of cure depth sample generation and measurement, while maintaining a high degree of measurement repeatability, reliability, and relevance to the printing process. Effects of multiple printing process variables are explored, including slurry dose, projected area, light intensity, and dry time. The impacts of measurement gauge, sample size, operator, and repeated measurements are also investigated. Results showing the impact of machine and material are included, demonstrating applicability to a wide audience.

2:50 PM
Binderless Additive Manufacturing of Ceramics by Selective Laser Flash Sintering: Matthew Cassoli¹; Desiderio Kovar¹; ¹University of Texas Austin
     Ceramic additive manufacturing processes use polymeric binders that are removed by pyrolysis before post-scan sintering. The time required for pyrolysis increases dramatically with part dimensions, which practically limits part size. Another challenge is that existing powder-based processes produce parts with limited relative densities, and thus relatively poor mechanical properties.Selective laser flash sintering (SLFS) is a binderless, direct additive manufacturing process being developed to additively manufacture high density ceramic parts. SLFS leverages flash sintering to allow for lower process temperatures, but microscale defects may be induced by thermal shock after laser scanning. In this study, cooling rates in the powder bed are measured after scanning and strategies are studied that reduce thermal gradients that cause cracking. Sample parts were fabricated and mechanical strengths compared for parts produced using standard laser scan strategies and using the modified strategies.

3:10 PM
Selective Laser Flash Sintering Using Scanning Fringing Field Electrodes in an Ionized Atmosphere: Joey Zamora¹; Desiderio Kovar¹; ¹The University of Texas at Austin


3:30 PM
Automated Fiber Segmentation and Characterization in Ceramic Composite Micrographs1: Andi Scarola¹; Jason McCleary¹; Carmen Gutierrez¹; Rosario Lara¹; Francisco Medina¹; ¹University of Texas at El Paso
    Fiber characterization in ceramic composite micrographs is important for understanding microstructural organization, but manual analysis is time-intensive, subjective, and challenging to scale. In addition, traditional semi-automated workflows such as ImageJ can become difficult to tune reliably for large micrographs with many features and complex background structures. This work presents an automated pipeline for fiber segmentation and characterization using overlapping tiled image processing, a U-Net-based model for fiber detection, and downstream analysis for estimating fiber density and orientation. Rather than shrinking the full micrograph before analysis, the system divides the image into overlapping tiles, so fine details can be preserved. During analysis, each tile is segmented separately, and the tile-level results are then combined back into a full-image output for downstream measurements such as fiber density and orientation. Evaluation is based on comparison with manual and ImageJ-based analysis to assess reproducibility in ceramic composite imaging.

3:50 PM
Short and Continuous Fiber Reinforced Non-Oxide Ceramics for Harsh Environment Applications: Yirong Lin¹; ¹University of Texas at El Paso
    Ceramic matrix composites (CMCs) reinforced with continuous carbon fibers (CCF) offer exceptional strength and thermal stability for extreme environment applications. However, conventional fabrication methods limit the ability to tailor their geometry and sensing functionality. This work investigates additive manufacturing of fiber-reinforced silicon carbide (SiC) and zirconium diboride (ZrB₂) CMCs to enable customized structural and sensing performance. Printed samples are characterized for mechanical properties, microstructure, and thermal behavior. Results demonstrate that AM enables precise control over fiber architecture and composition, directly influencing material response. This work advances the development of multifunctional CMC components capable of structural load-bearing and real-time condition monitoring.