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

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

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

    • 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 ceramicsMedical:• 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 © sirris 2012 | www.sirris.be | info@sirris.be | 3
    • Traditional manufacturing processTooling Injection Molding Hot Isostatic Pressing Size tolerance Mass production Simple parts <20k parts/year (>30k parts/year) Too many manipulation  dimensional limits  Too many manipulationfor complex parts (roughness) for complex parts Huge material losses  Mold releasable geometry Injection moulding is too expensive for short runs due to mould costs © sirris 2012 | www.sirris.be | info@sirris.be | 4
    • Example : medicalTo 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 © sirris 2012 | www.sirris.be | info@sirris.be | 5
    • 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 © sirris 2012 | www.sirris.be | info@sirris.be | 6
    • 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 © sirris 2012 | www.sirris.be | info@sirris.be | 7
    • Solutions - OptoformAdvantages :• 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; …) © sirris 2012 | www.sirris.be | info@sirris.be | 8
    • Solutions - OptoformImplantology test part in Hydroxyapatite Controlled macro porosity Complex mechanic parts (Alumina) – (>150 µm diameter) 20mm length © sirris 2012 | www.sirris.be | info@sirris.be | 9
    • Solutions - OptoformIntervertebral bone replacement (HA/TCP) Orbital floor with surrounding porosity (Hydroxyapatite) Cranial Implant with custom porosity and fixation devices (Hydroxyapatite) © sirris 2012 | www.sirris.be | info@sirris.be | 10
    • Solutions - Optoform Short run of sensor in Alumina (40mm length)Test part in Hap/TCP (Dia. 50mm) Alumina rings © sirris 2012 | www.sirris.be | info@sirris.be | 11
    • Solutions – 3DPrinting Zcorp with ceramic powder feeding systemAdvantages :• Large part• High Volume production ViriSheelTM Alumina/Silica CeramicDisadvantages : 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 © sirris 2009 | www.sirris.be | info@sirris.be | 12
    • Solutions - µSLAAdvantages :• 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 © sirris 2009 | www.sirris.be | info@sirris.be | 13
    • Thanks for your attentionTommaso SforzaProject EngineerTel. +32 4 361 87 11Gsm. +32 485 39 25 37tommaso.sforza@sirris.be © sirris 2012 | www.sirris.be | info@sirris.be | 14
    • © sirris 2009 | www.sirris.be | info@sirris.be | 15
    • How does it works? Ceramic Paste material Additive Debinding Sintering powder ManufacturingPowder : Granulometry Material purity Mix Hap powder (SEM x350) XR diffraction diagram (Hap) © sirris 2012 | www.sirris.be | info@sirris.be | 16
    • How does it works? Ceramic Paste Additive Debinding Sintering powder material Manufacturing Paste material:  Powder suspension  Rheology  Vol. % of ceramic powder © sirris 2012 | www.sirris.be | info@sirris.be | 17
    • How does it works? Additive Ceramic powder Paste material Manufactu Debinding Sintering ring Additive Manufacturing:  Sensitivity  Supports  Manufacturing parameters © sirris 2012 | www.sirris.be | info@sirris.be | 18
    • How does it works? Ceramic Additive powder Paste material Manufacturing Debinding Sintering Thermal debinding :  Resin removal  Supports © sirris 2012 | www.sirris.be | info@sirris.be | 19
    • How does it works? Ceramic Additive powder Paste material Manufacturing Debinding Sintering Sintering:  Shrinkage  Cracking  Grain size Sintering of ceramic powder( PicturesCNRS DAE) © sirris 2012 | www.sirris.be | info@sirris.be | 20
    • How does it works? Post- treatment Post-treatment :  machining  Post HIPing (high pressure and temperature densification)  Polishing © sirris 2012 | www.sirris.be | info@sirris.be | 21