Research Progress on Preparation Technology, Structure Optimization and Properties of 3D-Printed Porous Ceramics

Porous ceramics have garnered widespread attention in high-temperature insulation, aerospace, and other fields due to their excellent thermal stability, low density, and superior thermal insulation performance. However, traditional preparation technologies suffer from limitations such as poor pore structure controllability, unstable mechanical properties, and long production cycles. In recent years, 3D printing (additive manufacturing) technology has emerged as a disruptive approach to address these challenges, enabling precise fabrication of porous ceramics with complex structures and tailored properties. This review comprehensively summarizes the research progress on 3D-printed porous ceramics, focusing on preparation technologies, structure optimization, and performance regulation. First, the principles and drawbacks of traditional preparation methods are analyzed. Then, four mainstream 3D printing technologies (Binder Jetting, Material Extrusion, Vat Photopolymerization, and Material Jetting) for porous ceramics are elaborated on in terms of forming mechanisms, process characteristics, typical cases, and performance advantages/disadvantages. Additionally, the structure–property optimization strategies, including the design of Triply Periodic Minimal Surface structures and the application of computational modeling and simulation, are discussed to achieve the balance between thermal insulation and mechanical properties. Finally, current challenges and future development trends of 3D-printed porous ceramics are prospected. This review provides a systematic reference for the rational selection of preparation technologies, structural design, and performance optimization of porous ceramics, promoting their engineering applications in high-value fields.