2012 11-08-3 d-printing-event-ceramics

le centre collectif de l’industrie technologique belge

Additive Manufacturing for

Ceramic parts

ESMA – 8th of Novembre 2012

Additive Manufacturing Department (ADD)

Ceramics ?

© sirris 2012 | www.sirris.be | [email protected] | 2

Definition :

Inorganic and nonmettalic solid,

prepared by the action of heat.

Properties :

• High Hardness and low relative

density

• Excellent wear resistance and very

high heat resistance

• Electrical insulator

• Corrosion resistance

North American technical and advanced structural ceramics market

by application, 2012 – 2016 ($ millions) – BCC Research Freedonia

Growing interest in technical ceramics

Medical:

• Surgical tools,

• Bioabsorbable implant (sinus

lift, tibial osteotomy, bone

filling, …)

Industry :

• Aeronautics and space

• Defense

• Electronic and Electrical

engineering

• Chemistry and plastic

• Industrial Machinery


Traditional manufacturing process


Injection moulding is too expensive for short runs due to mould costs

Tooling Injection Molding Hot Isostatic Pressing

Size tolerance

<20k parts/year

Too many manipulation

for complex parts

Huge material losses

Mass production

(>30k parts/year)

dimensional limits

(roughness)

Mold releasable

geometry

Simple parts

Too many manipulation

for complex parts

Example : medical

To reach domain requirements, we need:

• Fast Manufacturing process

Injection Molding

• Custom-made implant to decrease treatment time

Hot Isostatic Pressing

• Competitive price vs alternative

Tooling ; Injection molding


Existing solution in AM ?


Not any additive manufacturing machine commercialized

allowing:

• Processing industrial volume of ceramic parts

• Processable material dedicated to existing machine

• High relative density (Nowadays only till 70% for large parts)

Main challenges:

• Binding system

• Shrinkage

AM solution under development !

Additive Manufacturing allows:

• Quick delivery time ! (within a

week)

• Low cost for short runs, small

parts or complex design

• No geometrical limitation

• Satisfying mechanical properties


OPTOFORM

Solutions - Optoform


Functional integrated fillet –

no post-manufacturing

(Alumina)

Advantages :

• Large part and small parts

• Medium Volume production

• Good relative density (up to 97%)

• Accuracy of final product:

0,3% for small parts (<50mm)up to 0,1mm

1% for big parts (50<x<200mm)

• Good surface roughness (50µm layer

thickness)

Disadvantages :

• Expensive cleaning process

• Only few developed material (Al2O

3;

Hap/TCP; SiC; …)


Implantology test part in Hydroxyapatite

Controlled macro porosity

(>150 µm diameter)


Complex mechanic parts (Alumina) –

20mm length


Cranial Implant with custom porosity

and fixation devices (Hydroxyapatite)

Intervertebral bone replacement (HA/TCP)


Orbital floor with surrounding porosity

(Hydroxyapatite)



Alumina rings

Test part in Hap/TCP (Dia. 50mm)

Short run of sensor in Alumina

(40mm length)

Solutions – 3DPrinting


Zcorp with ceramic powder feeding system

Zcorp 3DPrinter

ViriSheelTM

Alumina/Silica

Ceramic

Glossy Black Dinnerware by

Shapeways

Advantages :

• Large part

• High Volume production

Disadvantages :

• No strength part

• Low relative density obtained (approx.

70% density)

• Few processable material

• Low definition and surface roughness

(layer thickness 125µm)

http://static1.sw-cdn.net/rrstatic/img/materials/cer-blackglossy.jpg

Solutions - µSLA


Lithoz ceramic

part

Advantages :

• Very high accuracy (DLP optic

with 33µm/pixel)

• High relative density reached (>

95 %)

Disadvantages :

• Very small part

• Low production rate

• Few processable material

Lithoz stereolithography

machine

Thanks for your attention


Tommaso Sforza

Project Engineer

Tel. +32 4 361 87 11

Gsm. +32 485 39 25 37

[email protected]


How does it works?

Ceramic

powderPaste material

Additive

ManufacturingDebinding Sintering


Powder :

Granulometry

Material purity

Mix

Hap powder (SEM x350)

XR diffraction diagram (Hap)

Ceramic

powder

Paste

material

Additive



Paste material:

Powder suspension

Rheology

Vol. % of ceramic powder

How does it works?

Ceramic


Additive

Manufactu

ring

Debinding Sintering


Additive Manufacturing:

Sensitivity

Supports

Manufacturing parameters

How does it works?

Ceramic


Additive



Thermal debinding :

Resin removal

Supports

How does it works?

Ceramic


Additive



Sintering:

Shrinkage

Cracking

Grain size

Sintering of ceramic powder( PicturesCNRS DAE)

How does it works?

Post-

treatment


Post-treatment :

machining

Post HIPing (high pressure and temperature

densification)

Polishing

How does it works?

Documents

2012 11-08-3 d-printing-event-ceramics