With Carbon into New DimensionsAdditive Manufacturing with Carbon Materials and Post-Processing Technologies

CARBOPRINT™

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With carbon into new dimensions – made by SGL Group

SGL Group – The Carbon Company – is a leading global manufacturer of carbon- based products. We have wide-ranging expertise in raw materials, advanced manu- facturing processes, and longstanding application and engineering know-how. Focusing on the technological challenges of megatrends, like digitalization and individualization, we develop innovative carbon based solutions. With additive manufacturing we open new dimensions in respect to product design, performance and time-to-market.

3AddITIve mANufACTuRed CARBON COmPONeNTs

CARBOPRINT™ – Additive manu-facturing with carbon materials and post-processing technologies Classical carbon based components are made by machining, which is a standard “subtractive” process. In contrast, additive manufacturing, such as 3D printing, is an innovative, material efficient, layer by layer process. It opens up new dimensions of design freedom.

CARBOPRINT P Polymer carbon

composites

CARBOPRINT SiCeramic carbon

composites

CARBOPRINT CCarbon and graphite

CARBOPRINT M Metal carbon composites

Together with our partners and custo-mers we develop individual and new out of the box solutions for tomorrow.

The CARBOPRINT family combines our comprehensive carbon material know-how with additive manufacturing technology. In addition, our broad base of post-processing capabilities, such as metal, resin or silicon infiltration, delivers innovative material solutions for your applications.

This set of competencies and capabili-ties is a unique starting point for rapid and economic production of prototypes and small series of carbon based com-ponents for various industries such as glass, metal and chemicals, as well as high-temperature and mechanical applications.

CARBOPRINT material family a

Metal infiltration

Silic

onin

filtra

tion

Polymer

infiltration

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5AddITIve mANufACTuRed CARBON COmPONeNTs

Benefitting from unique carbon properties and additive manufacturing technology

Typical propertiesPost-processing Types Potential components

Advantages of additive manufacturing with binder jetting technology

Complex design at no additional cost (e. g. realization of undercuts and/or cavities)

Acceleration of developments and production launch of small series

Use of materials suitable for industrial applications Capabilty to produce large industrial components

Advantages of using carbon in additive manufacturing Carbon and graphite specific properties (e. g. low weight, electrical and thermal conductivity, mechanical strength, chemical and high-temperature stability, low thermal expansion)

Porous body structures deliver ideal basis for new material designs via metal, polymer or silicon infiltration

Intelligent functions are possible (e. g. heating and thermal management)

None/ Carbon infiltration

Polymer infiltration

Metal infiltration

Silicon infiltration

CARBOPRINT C

CARBOPRINT P

CARBOPRINT M

CARBOPRINT Si

Q Low densityQ Open porosityQ Isotropic homogenous structure

Q Complex designs with improved mechanical properties

Q Accelerated developmentQ Good gliding properties

Q High strength at elevated temperature

Q Good electrical and thermal conductivity

Q High hardness – low wearQ High temperature resistanceQ Good corrosion resistance

Q Casting coresQ Casting moldsQ Preforms

Q Electrical contactsQ Gliding elementsQ Pump partsQ ElectrodesQ Heat exchanger componentsQ HeatersQ Sealings

Q Casting moldsQ BearingsQ EDM electrodes

Q Pump impellers and casingsQ Burner nozzlesQ Heat exchangers

CARBOPRINT C

Freedom of (material)

design

Lightweight – low density,

open porosity

Processable like additive

manufacturing sands

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Carbon and graphite powders are the basis for cost-efficient serial production of carbon and graphite based components. Their porous bodies are binded with chemically and thermally stable duroplastic binder systems – all with help of SGL Group‘s established processes and know-how.The highly porous carbon structure of CARBOPRINT C bodies is an ideal basis for post-processing, such as infiltration with silicon, or impregnation with polymers and metals.

CARBOPRINT™ C Carbon and graphite components

d Porosity of printed carbon delivers ideal basis for refinement

b Carbon powder as the basis material

Typical material data for our CARBOPRINT™ C

Typical properties Units C1Density g/cm³ 1.0Open porosity % 40 – 50E-modulus GPa 2Flexural strength MPa 5Electrical resistivity Ωµm 125000Thermal conductivity W/(mK) <1CTE (at RT/150 °C) µm/(mK) 5.5

CARBOPRINT P

Heating functions Thermal properties

of carbon and resins

CTE CTE lower than pure polymers

Temperature stability

Heat resistant < 200 °C

New material designs

Infiltration of carbon with polymers, i. e. resins

Lightweight Porous carbon structure and

low weight resins

Electrical and thermal conductivityAdjustable and high

conductivities possible

7AddITIve mANufACTuRed CARBON COmPONeNTs

Applications that require non-metallic materials will profit significantly from polymer carbon composites.This material is temperature resistant up to 200 °C – without creeping effects common among other polymers. Depending on the choice of polymer, properties such as mechanical or chemical stability can be adjusted to customer requirements.

CARBOPRINT™ P Polymer carbon composites

a Choice of polymer increases material design variability

Typical material data for our CARBOPRINT™ P

Typical properties Units P1 P2Density g/cm³ 1.58 1.4E-modulus GPa 6 6Flexural strength MPa 15 45Electrical resistivity Ωµm 35 100000Thermal conductivity W/(mK) 40 <1CTE (at RT/150 °C) µm/(mK) 12 40

d Sample part infiltrated with polymers

CARBOPRINT Si

Established manufacturing

Key know-how in post-processing,

i. e. infiltration

Low CTE,high precision

Temperature resistance

Up to 1200 °C and against thermo-

shocks High hardness Strong resistance against abrasion

Lightweight Low density due to

porous carbon structure and silicon

Chemical stabilityGood oxidation and chemical resistance

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Ceramic carbon composites provide ideal properties when it comes to reliable function and longevity in harsh environments and at high temperatures. We bring decades of experience with ceramic composites to additive manufacturing, in order to provide our customers the opportunity to realize almost any design with ceramic carbon composites. CARBOPRINT SI components are made by siliconi-zing CARBOPRINT C bodies.

CARBOPRINT™ Si Ceramic carbon composites

c Silicon used in our infiltration process

Typical material data for our CARBOPRINT™ Si

Typical properties Units Si1Density g/cm³ 2.3 Open porosity Vol.-% <0.1 E-modulus GPa 35 Flexural strength MPa 60 Elongation at break % 0.25 Bending energy absorption Nmm 340 Electrical resistivity Ωµm 20Thermal conductivity W/(mK) 50CTE (at RT/200 °C) µm/(mK) 3Silicon carbide content wt.-% 25 Silicon free content wt.-% 35Carbon content wt.-% 40

d Pump impeller in CARBOPRINT Si

CARBOPRINT M

Simplicity No specialized metal powder

necessary

CTELower CTE

than pure metals

Thermal & electrical properties adjustablecombining carbon and

metal advantagesFlexibility

Available choice of metals depending

on component function

Lightweight Lower density

than that of pure metals

Lower wearGood gliding

properties

9AddITIve mANufACTuRed CARBON COmPONeNTs

Metal carbon composites are designed for purposes where the combination of metal and carbon properties are needed.They are suitable for applications in elevated temperature environments, where good electrical conductivity and/or where low friction is needed.

CARBOPRINT™ M Metal carbon composites

d Sample parts in CARBOPRINT M

Typical material data for our CARBOPRINT™ M

Typical properties Units M5Density g/cm³ 3.0E-modulus GPa 23Flexural strength MPa 20Electrical resistivity Ωµm 5CTE (at RT/200 °C) µm/(mK) 6Carbon content Vol.-% 60Metal content Vol.-% 30Pores Vol.-% 10

b Antimon for metal impregnation

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Additive manufacturing technology and post-processing expertise combinedFrom individual requirements to customized solutions.

Understanding the application requirements Connecting customer’s design needs with material specifications

Integrating additive manufacturing expertise and design Selecting composite and related post-processing options with resin, silicon or metal impregnation

Processing the order with partner On-demand order management or long-term production

Project initiation Binder jetting technology

c Additive manufacturing process (binder jetting) – building up the carbon body layer-by-layer

c Customer design file in 3D-CAD format (source: ExOne GmbH)

CARBOPRINT™ family: typical material properties at a glance

Typical properties Units CARBOPRINT C CARBOPRINT Si CARBOPRINT P CARBOPRINT MDensity g/cm³ 1.0 2.3 1.4 – 1.6 3.0E-modulus GPa 2 35 6 23Flexural strength MPa 5 60 15 – 45 20Electrical resistivity Ωµm 125000 20 35 – 100000 5Thermal conductivity W/(mK) <1 50 <1 – 40CTE (at RT 150 /200 °C) µm/(mK) 5.5 3 12 – 40 6

Polymer infiltration

Polymer carbon compositesCARBOPRINT P

Metal infiltration

Metal carbon composites CARBOPRINT M

Silicon infiltration

Ceramic carbon compositesCARBOPRINT Si

Additive manufacturing of carbon CARBOPRINT C

Optional: carbonization/redensification/graphitization

11AddITIve mANufACTuRed CARBON COmPONeNTs

Product refinement Infiltration with polymer or metal or silicon Finishing Delivery

Post-processing steps

c Silicon infiltrated pump impellerc Polymer infiltrated part c Metal infiltrated rings

If you want to combine the unique properties of carbon and graphite with the advantages of additive manufacturing tech-nology, SGL Group will be your partner of trust.Our start into this new era of manufacturing has just begun.

We encourage industrial partners with “pioneer” spirit, such as engineers and designers, to develop innovative carbon-based components with us to gain a significant competitive advantage. Join us on the discover journey to new carbon based dimensions!

™ pending trademark application of SGL CARBON SE 01 2016/1 E Printed in GermanyThis information is based on our present state of knowledge and is intended to provide general notes on our products and their uses. It should therefore not be construed as guaranteeing specific properties of the prod-ucts described or their suitability for a particular application. Any existing industrial property rights must be observed. The quality of our products is guaranteed under our “General Conditions of Sale”.

Contact

Technology & InnovationSGL CARBON GmbHWerner-von-Siemens-Strasse 1886405 Meitingen/Germanywww.sgl-carboprint.com

SGL CARBON GmbHWerner-von-Siemens-Strasse 1886405 Meitingen/GermanyPhone +49 8271 83-3523CARBOPRINT@sglgroup.com