New 3D printing method grows ultra-strong ceramics from hydrogel
EPFL researchers have pioneered a 3D printing method that grows metals and ceramics inside a water-based gel, resulting in exceptionally dense, yet intricate constructions for next-generation energy, biomedical, and sensing technologies (Photo: EPLF)
October 8, 2025 – Researchers at EPFL have developed a new 3D printing technique that produces exceptionally strong and dense ceramic or metal structures using a simple water-based hydrogel. The method, created by Daryl Yee’s team at the Laboratory of Materials and Manufacturing Chemistry, overcomes long-standing problems in ceramic production such as shrinkage, warping and porosity.
The process begins with printing a lightweight hydrogel framework, which is repeatedly infused with metal or silica salts. These salts convert into ultrafine ceramic particles that fill the structure and make it progressively denser. After several cycles, the gel is removed by heating, leaving a compact, high-strength ceramic that exactly matches the original printed shape.
