Segula Technologies makes it possible to 3D print glass at room temperature

The engineering group Segula Technologies has just developed a new process for manufacturing a hybrid, versatile form of glass with fully customisable properties.

Based on sol-gel chemistry (short for ‘solution-gelation’), which gives materials high mechanical strength, the innovation consists of a new drying process in a liquid medium enabling the additive manufacturing of all kinds of hybrid glass components at room temperature or low temperatures (100 to 150° C), without the need for melting or traditional sintering at temperatures exceeding 1000° C.

A genuine technological breakthrough, this process enables the production – via both moulding and additive manufacturing, and without high tooling costs – of complex parts with geometries that were previously impossible to achieve. The resulting parts possess unique properties that are fully customisable in terms of density, porosity, elasticity and optical transmittance.

Consequently, this process makes it possible to control the variability of the material’s mechanical, optical and chemical characteristics within a single part; for example, a ‘sandwich’ type structure combining flexibility and rigidity within a single assembly, without any joints or interfaces.

Developed in collaboration with the Multimaterials and Interfaces Laboratory (LMI) on the LyonTech-la Doua campus in Villeurbanne, the process has a Technology Readiness Level (TRL) ranging from three to six depending on its field of application, with demonstrations of representative functional prototypes, and is the subject of a patent (FR No. 2505395).

Mathieu Orzalesi, regional research and development manager at Segula Technologies, explained: ‘We describe the material produced using our new process as glass because it is structurally made from silica precursors, just like the conventional glass we use in everyday life. However, it offers all the versatility of plastic, particularly its malleability and elasticity, without its major drawbacks such as thermal instability or poor resistance to solvents. It is for all these reasons that this new glass represents a particularly innovative and high performance mineral alternative for industry. To our knowledge, no one has ever created such a versatile material; it is a real feat of which we are particularly proud!’

This innovative process enables the creation of a range of bespoke materials that address the key challenges of safety, sustainability and weight reduction in cutting edge industries such as the automotive, aerospace, rail, energy and biotechnology sectors.

Some examples include:

• Hybrid glass for smart components: this new material can be shaped and encapsulated at room temperature, enabling the manufacture of complex optical lenses and the direct integration of smart sensors.

• Technical coatings for surface durability (glass, metals, etc.): as a mineral alternative to polymers, they enable the creation of transparent materials that are resistant to UV light, solvents and acids, and are suited to the extreme environments encountered in transport.

• Mineral cellular foams for electrical and thermal insulation: capable of withstanding temperatures of up to 300 °C, they could be used to insulate electric vehicle batteries, thereby eliminating the risks of thermal deformation, wear and toxicity associated with traditional polyurethane foams.

The process also opens up new possibilities in technical design and architecture, particularly for the creation of transparent objects with complex geometries, produced using 3D printing or moulding.

With this major innovation, Segula reaffirms its role as a provider of bespoke solutions for its industrial clients.