Sacrificial 3-dimensional weaving method and ceramic matrix composites formed therefrom

A method of forming a ceramic matrix composite (CMC), the method comprising:

• providing a woven layer comprising a first set of ceramic fibers oriented in a first (x) direction woven with a second set of ceramic fibers oriented in a second (y) direction:
• stacking a plurality of woven layers on top of each other, said woven layers providing a two-dimensional (2-D) preform;
• weaving a set of sacrificial fibers in a third (z) direction with the 2-D preform, said weaving providing the 3-D woven preform;
• and
• shaping the 3-D woven preform into a predetermined shape;
• removing the set of sacrificial fibers from the 3-D woven preform;
• and
• infiltrating the 3-D woven preform with a metal or metal alloy to form the ceramic matrix composite (CMC);
• wherein the metal or metal alloy fills any gaps or free volume that is located between the first and second sets of ceramic fibers.