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Design 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 sufficient strength for subsequent handling. Depending on the need, this shaped, unfired powder heap (green compact or green body) can be processed inexpensively before firing, since the corresponding work steps after firing are much more complex. In the various methods of shaping, care must be taken to ensure that there are no noticeable density gradients and textures in the green compact, because they can be caused by fire. U. can reinforce it, lead to deformation and cause internal mechanical stresses. The selection of the suitable shaping process is usually based on economic considerations (efficient production).

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

  • Pressing (0 - 15% moisture)

  • Plastic shaping (15 - 25% moisture)

  • Pouring (> 25% moisture)

We are happy to support you in realizing your parts with this process.

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DRY PRESSES

Dry pressing is used for the production of mass-produced articles that are accurate to size. In the process, free-flowing granulates are compacted in steel matrices that are profiled according to the part to be produced. The high costs for the tool (partly made of hard metal) are usually only justified for large series.

Dry pressing is the most economical process for large quantities and is suitable for simple to complex geometries. Pressed-in recesses and bores are normally only to be provided in the pressing direction.
Depending on the design of the automatic dry pressing machine, components ranging in size from tiles to match heads can be realized. Small discs or plates can be pressed up to a thickness of approx. 0.8 to 1 mm. For even thinner, flat components, the film casting process is more suitable. 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 are happy to support you in realizing your parts with this process.

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ISOSTATIC PRESSING

Isostatic pressing is used to produce evenly compressed blanks and large bodies that are suitable for subsequent machining in the green state. Simple rubber forms initially require simple raw forms.

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

We are happy to support you in realizing your parts with this process.

EXTRUDING

Extrusion takes place using piston extrusion or vacuum screw presses. The homogenized mass is pressed through a mouthpiece and formed into continuous strands. Optimal compaction of the mass is important.
With extrusion, rotationally symmetrical parts such as axles or pipes can be produced particularly well. Complicated profiles are also feasible with an appropriate mouthpiece design. The lengths of the strands to be produced essentially depend on the tendency of the working mass to warp.

We are happy to support you in realizing your parts with this process.

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INJECTION MOLDING

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

The tool costs are absolutely justified, since the series parts are produced in a very high quality.

The delivery rate (“shot weight”) is typically up to 70 g in the large injection molding machines. In principle, the wall thickness should be designed as evenly as possible and limited to approx. 12 mm above.

Typical injection molded products:

  • Textile components such as ceramic thread eyelets

  • Machine components such as ceramic coffee grinders

  • Watch industry such as ceramic watch cases or bezels

  • Medical technology such as ceramic dental implants and abutments

  • and much more ...

We are happy to support you in realizing your parts with this process.

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MICRO INJECTION MOLDING

Micro injection molding is becoming more and more popular, as small parts, smaller than 4mm, can now be realized in technical ceramics.

Typical micro injection molded products:

  • Dental technology such as ceramic bracket

  • Bonding industry like the smallest wire guides

  • Watch industry like ceramic gears

  • and much more ...

We are happy to support you in realizing your parts with this process.

3D PRINT IN CERAMICS

The 3D printers designed for industrial production, which are based on lithography-based ceramic manufacturing (LCM) technology, enable reliable series production of additively manufactured ceramics. Our 3D printers meet the highest requirements for high-performance ceramics. The mechanical performance, dimensional accuracy and reproducibility of ceramic components meet or even exceed those of components from conventional production.

Starting with a CAD model, the first step in the process is work preparation and optimization. The information for the job is digitally transmitted directly from your computer.

The ceramic-loaded liquid (slip) is automatically dosed and applied to a transparent tub. The movable construction platform is immersed in the slip, which is then selectively exposed to visible light from below the tub. The layer image is generated by a digital micromirror device (DMD) in conjunction with a state-of-the-art projection system. By repeating this process, a three-dimensional green part can be created layer by layer.

The LCM technology uses decades of experience in processing ceramic powders. By using the same powders and ovens as in injection molding, ceramic components with excellent mechanical properties and surface qualities are produced. After the thermal post-processing, the binder is removed and the components are sintered, creating completely dense ceramic components.

We are happy to support you in realizing your parts with this process.

If you would like to send us your request or if you have general questions, we ask you to inform us without hesitation when you call or send them by email.

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