CAREER: Enabling Single-Step Additive Manufacturing of Ceramics via Laser-Triggered Flash Sintering and Scientific Artificial Intelligence-based Multiscale Modeling

NSF Award Search · 01002627DB NSF RESEARCH & RELATED ACTIVIT · $550,000 · view on nsf.gov ↗

Abstract

Ceramics possess exceptional resistance to heat, wear, radiation and corrosion, yet their widespread adoption is limited because direct manufacturing complex ceramic parts requires extremely high temperatures and often leads to cracking, defects, and long processing times. This Faculty Early Career Development Program (CAREER) award supports research in additive manufacturing (AM) of high-performance ceramics to enable faster, more reliable production of components used in aerospace, nuclear energy, electronics, and biomedical systems. Current AM methods either rely on multi-step processes that are slow and prone to distortion or single-step methods that generate severe cracking and poor material quality. Research enabled by this award seeks to overcome these limitations by developing a new AM approach that enables rapid, defect-resistant fabrication of complex components. By advancing reliable manufacturing of high-performance ceramics, the award is expected to accelerate innovations in energy efficiency, advanced transportation, and resilient infrastructure, strengthening U.S. technological leadership, economic competitiveness, and national security.    This CAREER award aims to establish the scientific foundation for a transformative single-step ceramic AM process based on laser-triggered flash sintering (LTFS). A central challenge is the lack of fundamental understanding of how coupled laser heating and electric-field stimulation initiate flash sintering, govern densification kinetics, and influence microstructure evolution, defect formation, and process reliability. To address this gap, research is planned to develop an integrated experimental, computational, and data-driven framework. Specifically, the research tasks include (1) design and construct an LTFS-enabled AM testbed with in-situ monitoring for real-time process characterization; (2) investigate flash-sintering initiation, stability, and microstructure evolution through coordinated experiments and m

Key facts

NSF award ID
2543492
Awardee
University of Maryland, College Park (MD)
SAM.gov UEI
NPU8ULVAAS23
PI
Lin Cheng
Primary program
01002627DB NSF RESEARCH & RELATED ACTIVIT
All programs
CAREER-Faculty Erly Career Dev, MATERIALS PROCESSING AND MANFG, Materials Engineering, Advanced Manufacturing, UNDERGRADUATE EDUCATION, GRADUATE INVOLVEMENT, MANUFACTURING
Estimated total
$550,000
Funds obligated
$550,000
Transaction type
Standard Grant
Period
09/01/2026 → 08/31/2031