Continuous basalt fibers into fireproof and thermal insulation architectures using an additive manufacturing manipulator

Continuous basalt fiber is an emerging high-performance foundational material that can be widely used in fields such as road construction, energy conservation and environmental protection, aerospace, military equipment, and marine ships. However, it is difficult for existing processing techniques to form continuous basalt architectures with three-dimensional (3D) complex shapes. In addition, the basalt fibers in the architectures are filled with polymers, which cannot fully utilize the performance of basalt fibers. Therefore, here, we report the fabrication of continuous basalt fibers with fireproof and thermal insulation performance through the combination of an Additive manufacturing (AM) manipulator, two-step precursor infiltration and pyrolysis (PIP) processes. Using SiOC ceramics to fill between continuous basalt fibers will help improve the architectures' fire and thermal insulation performance. The continuous basalt fibers coated with thermoplastic polyurethanes (TPU) were processed into 3D architectures under the action of the laser. Through the vacuum infiltration of the SiOC precursor and debinding process, TPU in the 3D architectures was removed. In order to reduce the structural defects generated by the first PIP process, the final part with fireproof and thermal insulation performance was fabricated through the second PIP process. We further demonstrated the final part with excellent fireproof and thermal insulation performance. The final part had a shell temperature of 788.8 ℃ and an internal temperature of about 50 ℃ under the flame spray gun for the 20 s. By replacing polymers with inorganic materials, our basalt architectures exhibit their potential applications in military, aviation, and civil fireproof and thermal insulation equipment.