Additive manufacturing (AM) technologies allow for the creation of components with greater design flexibility. The complexity in geometry and composition can enhance functionality, while parts made from multiple materials have the capacity to deliver improved performance. Nonetheless, most multimaterial printing methods are still in their infancy and face numerous challenges. Numerous materials require individual post-treatment, and some may not be compatible with each other regarding shrinkage, melting or sintering temperatures, and interactions. In this study, we introduce a technique for producing a metal–ceramic multimaterial prototype for electronic packages through powder-bed additive manufacturing technology. Silicon carbide-based ceramic substrate was manufactured by selective laser melting, on which molybdenum-based conductive tracks were printed. The results indicated that the SiC-based samples exhibit a relatively uniform microstructure with homogeneously distributed porosity. Mo-based powder containing 5% silicon was successfully SLM-ed on the SiC layer. The microstructural and chemical analyses show that Mo reacted with Si during selective laser melting, resulting in formation of molybdenum silicides. The surface of Mo-based layer surface is smooth; however, there are few cracks on it. The Vickers hardness was measured to be 7.6 ± 1 GPa. The electrical resistivity of the conductive track is 2.8 × 10⁻⁵ Ω·m.

Additive manufacturing (AM) technologies allow for the creation of components with greater design flexibility. The complexity in geometry and composition can enhance functionality, while parts made from multiple materials have the capacity to deliver improved performance. Nonetheless, most multimaterial printing methods are still in their infancy and face numerous challenges. Numerous materials require individual post-treatment, and some may not be compatible with each other regarding shrinkage, melting or sintering temperatures, and interactions. In this study, we introduce a technique for producing a metal-ceramic multimaterial prototype for electronic packages through powder-bed additive manufacturing technology, specifically selective laser melting (SLM). A composite based on silicon carbide was created. The powder was removed from the chamber to prevent cross-contamination, and molybdenum-based powder was introduced. Molybdenum tracks with a diameter of 400μm and a length of 15mm were produced using SLM on a SiC layer. The results indicated that the SiC-based samples exhibit a relatively uniform microstructure with homogeneously distributed porosity. Mo-based powder containing 5% silicon was successfully SLM-ed on SiC layer. The surface of Mo layer surface is smooth with some cracks. The microstructure and chemical analysis of the layer was performed. The Vickers hardness was measured.

Additive manufacturing of copper alloys remains challenging due to their high reflectivity and thermal conductivity, which limit laser energy absorption and increase energy consumption. In this study, the laser powder bed fusion of a copper-based CuNi2.5SiCr alloy is demonstrated using low laser powers (67.2–100.8 W). Samples fabricated at 67.2 W achieved a relative density of 96.8%, with no significant improvement observed at higher laser powers. The post-process heat treatments were conducted at 750 °C, 850 °C, and 950 °C to investigate their influence on microstructure, hardness, electrical and thermal conductivity. Heat treatment at 850 °C resulted in the highest hardness, improved microstructural uniformity and 20 W/mK thermal conductivity, while the as-fabricated samples exhibited the highest electrical conductivity (1.07 × 10⁶ S/m).

Additive manufacturing of silicon carbide (SiC) is challenging due to uncontrollable quality, surface roughness of fabricated parts, expensive post-processing, and long production times for customized components. Developing cost-effective, rapid manufacturing techniques that maintain high quality and design freedom is therefore highly desirable. In this study, laser powder bed fusion (LPBF) followed by ultra-fast post heat treatment was applied to produce SiC-based composites using silicon and carbon powders as raw materials. The influence of processing parameters on silicon-carbon reaction and sintering was investigated. Boron carbide was used as an additive to enhance sintering. Substantial SiC formation occurred despite the limited heating time. Boron carbide influenced both SiC formation and grain growth. The maximum Vickers hardness (1218 HV0.2) was achieved in boron carbide-containing heat-treated samples printed at a laser power of 48 W. This novel approach enables the efficient fabrication of SiC-based composites with enhanced hardness, underscoring the potential of LPBF for cost-effective and customizable ceramic component manufacturing.