Ceramic Components

Custom 3D Printed Ceramic Components

Steinbach’s Form Ceram department produces highly precise ceramic components with impeccable quality in every detail. The 3D manufacturing process of Form Ceram eliminates the obstacles of small-batch, high-precision production and Steinbach’s innovative LCM process delivers prototypes that meet the quality requirements of large-scale production. This dramatically expands the capabilities of technical ceramics for:

  • Analysis and Measurement Equipment
  • Microreactors/Microfluidic Applications
  • Corrosion Resistant Parts for the Chemical Industry
  • Protection Devices for Sensors
  • High-temperature Applications
  • Micro-electronics
  • Plasma Technology

Take advantage of Steinbach’s technical expertise
for your one-of-a-kind needs.

Let Form Ceram’s capabilities in design-driven manufacturing work for you!

  • Prototyping with Large-Scale Production Quality
  • Single Item and Small Series Production
  • Reduction of Time-to-Market
  • Surface Roughness RA=0.4 without Post Processing
  • No Tooling Costs
  • >99% of Theoretical Density
  • Complex Geometries Possible

 

Ceramic Materials Details

Technical ceramic components exhibit a high mechanical, chemical, thermal and electrical resistance.
Ceramic materials are inorganic, non-metallic materials and, by definition, are at least 30% crystalline.
A ceramic material is defined by the process of forming and subsequent sintering, typically at over 800°C, whereby sintering determines the final properties of the material.

Ceramic Production Know-How

Additive Manufacturing

Using our own LCM process (Lithography-based Ceramic Manufacturing), we are able to produce almost any geometry otherwise impossible with other forming methods. As this process avoids tooling costs, we can accommodate quantities as low as 1.

Injection Moulding

For injection moulding, a warm feedstock, consisting of a ceramic powder mixed with a thermoplastic binder, is injected into a cold mould, where it hardens. Ceramic injection moulding ensures low-cost production of large batches of small parts with a complex geometry. Small batches are not cost-effective due to the rather high tooling costs for injection moulding.

Extrusion

Using a screw extruder, the material is pushed through a die to produce a continuous section. Its geometry may be complex but allows only two dimensions. Extrusion is a highly cost-efficient forming method particularly for rotationally symmetrical geometries such as pipes.

Dry Pressing – Uniaxial

The powder or granules are filled into a mould and pressed with a hydraulic press. This method ensures short machine cycles with excellent dimensional accuracy. Long-pitch pressure strokes can, however, result in uneven compaction. Uniaxial dry pressing therefore lends itself to the production of flat parts with complex geometries.

Dry Pressing – Isostatic

The ceramic material is evenly compacted in a flexible mould in the pressure container, before the green body is shaped through cutting. The result ensures a high degree of flexibility and dimensional stability of the geometry. Isostatic dry pressing is used, for example, for the production of artificial hip joints.

Tape Casting

Some applications require a ceramic material in the form of a very thin tape. This is the case for substrates, condensers, piezo elements and sensors. Tape casting offers the ideal solution here. The slurry for tape casting consisting of ceramic particles and an organic binder is spread in a thin layer onto a carrier film. Once dry, the film exhibits leather-like qualities and can be stamped, laminated and cut to achieve the required geometry after firing.