shaping of technical ceramics

Dry pressing

Isostatic pressing

Extrude

Ceramic injection molding

Micro ceramic injection molding

Foil casting

3D ceramic printing

SHAPING

Here, the powder particles are compressed and brought into a coherent shape that has enough strength for subsequent handling. Depending on the need, this shaped, unfired powder pile (green body or green body) can be processed inexpensively before firing, since corresponding work steps after the firing are much more complex. With the various shaping processes, care must be taken to ensure that there are no noticeable density gradients and textures in the green body, because these may U. still reinforce, lead to deformation and can cause internal mechanical stresses. The selection of the suitable shaping process is usually based on economic considerations (rational production).

The ceramic molding processes can be divided into the following basic types:

 

  • Pressing (0 - 15% moisture)

  • Plastic shaping (15 - 25% moisture)

  • Casting (> 25% moisture)

 

We would be happy to support you in realizing your parts using this process.

Dry pressing

Dry pressing is used for the manufacture of mass-produced items. Well pourable granules are compressed in steel matrices, which are profiled according to the part to be manufactured. The high costs for the tool (partly made of hard metal) are usually justified only for large series.

 

For large quantities, dry pressing is the most economical process and suitable for simple to complicated geometries. Pressed-in depressions and bores are normally only to be provided in the pressing direction.
Depending on the design of the dry press machine, components from tile to match head size can be realized. Small disks or platelets can be pressed up to a thickness of approx. 0.8 to 1 mm. The film casting process is more suitable for even thinner, flat components. Fine webs or the like in the component can still be produced if the press granulate used can reasonably fill the cavities in the press tool or if the tool design is possible.

 

We would be happy to support you in realizing your parts using this process.

Press isostatically

Isostatic presses are used to produce evenly compacted blanks and large bodies that are suitable for subsequent machining in the green state. Simple rubber molds initially require simple raw molds.

 

This shape is recommended for demanding prototype and small series production, but it can also be fully automated for certain products (spark plugs, grinding balls, smaller pistons, welding nozzles).

 

We would be happy to support you in realizing your parts using this process.

Extrude

Extrusion is carried out using piston extrusion or vacuum screw presses. The homogenized mass is pressed through a mouthpiece and thus formed into endless strands. Optimal compaction of the mass is important.
With extrusion, rotationally symmetrical parts such as axes or pipes can be produced particularly well. Even complicated profiles are feasible if the mouthpiece is designed accordingly. The lengths of the strands to be produced essentially depend on the tendency of the working mass to warp.

 

We would be happy to support you in realizing your parts using this process.

injection molding

Injection molding is basically suitable for the mass production of complicated parts.

The tool costs are absolutely justified because the series parts are manufactured in very high quality.

The delivery rate ("shot weight") is typically up to 70 g for the large injection molding machines. In principle, the wall thicknesses should be designed as evenly as possible and the ceiling should be limited to approx. 12 mm.

 

Typical injection molded products:

  • Textile components such as ceramic thread eyelets

  • Machine components such as ceramic coffee grinder disks

  • Watch industry such as ceramic watch cases or bezels

  • Medical technology such as ceramic, dental implants and abutments

  • and much more ...

 

We would be happy to support you in realizing your parts using this process.

 

Micro injection molding

Micro injection molding is becoming increasingly popular, since small parts smaller than 4mm can now be made in technical ceramics.

 

Typical micro injection molded products:

  • Dental technology like ceramic bracket

  • Bonding industry like the smallest wire guides

  • Watch industry like ceramic gears

  • and much more ...

 

We would be happy to support you in realizing your parts using this process.

Foil casting

Here, a ceramic slip with various organic additives is poured onto an endless steel belt driven by rollers. This means that the slip runs continuously from a storage container through an adjustable gap onto the belt. Warm air is blown over the film for drying in countercurrent, so that a green film that is flexible due to the organic additives is obtained at the end of the belt. This can either be wound up and stored for later processing or processed directly by cutting, punching, embossing or similar.
Typically, ceramic parts with a thickness in the range of 0.25 to 1.0 mm can be produced by film casting. The molded parts are suitable for the production of substrates, housings, capacitors and multilayer actuators.

 

We would be happy to support you in realizing your parts using this process.

3d printing in ceramics

Here, a ceramic slip with various organic additives is poured onto an endless steel belt driven by rollers. This means that the slip runs continuously from a storage container through an adjustable gap onto the belt. Warm air is blown over the film for drying in countercurrent, so that a green film that is flexible due to the organic additives is obtained at the end of the belt. This can either be wound up and stored for later processing or processed directly by cutting, punching, embossing or similar.
Typically, ceramic parts with a thickness in the range of 0.25 to 1.0 mm can be produced by film casting. The molded parts are suitable for the production of substrates, housings, capacitors and multilayer actuators.

 

We would be happy to support you in realizing your parts using this process.

If you would like to send us your request or if you have any general questions, please do not hesitate to let us know when you call or to send us an email.

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