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

Additive Manufacturing Department (ADD)

Additive Manufacturing for
Ceramic parts

ESMA – 8th of Novembre 2012

le centre collectif de l’industrie technologique belge

Ceramics ?

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

© sirris 2012 | www.sirris.be | info@sirris.be | 2

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
North American technical and advanced structural ceramics market
• Industrial Machinery by application, 2012 – 2016 ($ millions) – BCC Research Freedonia


Traditional manufacturing process

Tooling Injection Molding Hot Isostatic Pressing

 Size tolerance Mass production Simple parts
 <20k parts/year (>30k parts/year)

 Too many manipulation  dimensional limits  Too many manipulation
for complex parts (roughness) for complex parts
 Huge material losses  Mold releasable
geometry

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


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

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 Functional integrated fillet –
thickness) no post-manufacturing
(Alumina)

Disadvantages :
• Expensive cleaning process
• Only few developed material (Al2O3;
Hap/TCP; SiC; …)



Implantology test part in Hydroxyapatite

Controlled macro porosity Complex mechanic parts (Alumina) –
(>150 µm diameter) 20mm length



Intervertebral bone replacement (HA/TCP)

Orbital floor with surrounding porosity
(Hydroxyapatite)

Cranial Implant with custom porosity
and fixation devices (Hydroxyapatite)


Short run of sensor in Alumina
(40mm length)

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

Alumina rings


Solutions – 3DPrinting

Zcorp with ceramic powder feeding system

Advantages :
• Large part
• High Volume production
ViriSheelTM Alumina/Silica
Ceramic
Disadvantages :
Zcorp 3DPrinter
• No strength part
• Low relative density obtained (approx.
70% density)
• Few processable material
• Low definition and surface roughness
(layer thickness 125µm)

Glossy Black Dinnerware by
Shapeways

Solutions - µSLA

Advantages :
• Very high accuracy (DLP optic
with 33µm/pixel)
• High relative density reached (>
95 %)

Disadvantages : Lithoz ceramic
part
• 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
tommaso.sforza@sirris.be


How does it works?

Ceramic Paste material
Additive
Debinding Sintering
powder Manufacturing

Powder :
 Granulometry
 Material purity
 Mix
Hap powder (SEM x350)

XR diffraction diagram (Hap)


How does it works?

Ceramic Paste Additive
Debinding Sintering
powder material Manufacturing

Paste material:
 Powder suspension
 Rheology
 Vol. % of ceramic powder


How does it works?

Additive
Ceramic
powder
Paste material Manufactu Debinding Sintering
ring

Additive Manufacturing:
 Sensitivity
 Supports
 Manufacturing parameters


How does it works?

Ceramic Additive
powder
Paste material
Manufacturing Debinding Sintering

Thermal debinding :
 Resin removal
 Supports


How does it works?

Ceramic Additive
powder
Paste material
Manufacturing
Debinding Sintering

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


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

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