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Additive Manufacturing Department (ADD)                        Additive Manufacturing for                        Ceramic p...
Ceramics ?Definition :Inorganic and nonmettalic solid,prepared by the action of heat.Properties :•   High Hardness and low...
Growing interest in technical ceramicsMedical:•   Surgical tools,•   Bioabsorbable implant (sinus    lift, tibial osteotom...
Traditional manufacturing processTooling                    Injection Molding                      Hot Isostatic Pressing...
Example : medicalTo reach domain requirements, we need:•   Fast Manufacturing process     Injection Molding•   Custom-mad...
Existing solution in AM ?Not any additive manufacturing machine commercialized  allowing:• Processing industrial volume of...
AM solution under development !                  Additive Manufacturing allows:                  • Quick delivery time ! (...
Solutions - OptoformAdvantages :• Large part and small parts• Medium Volume production• Good relative density (up to 97%)•...
Solutions - OptoformImplantology test part in Hydroxyapatite                        Controlled macro porosity          Com...
Solutions - OptoformIntervertebral bone replacement (HA/TCP)                                                              ...
Solutions - Optoform                                   Short run of sensor in Alumina                                   (4...
Solutions – 3DPrinting   Zcorp with ceramic powder feeding systemAdvantages :• Large part• High Volume production         ...
Solutions - µSLAAdvantages :• Very high accuracy (DLP optic  with 33µm/pixel)• High relative density reached (>  95 %)Disa...
Thanks for your attentionTommaso SforzaProject EngineerTel. +32 4 361 87 11Gsm. +32 485 39 25 37tommaso.sforza@sirris.be  ...
© sirris 2009 | www.sirris.be | info@sirris.be |   15
How does it works?    Ceramic     Paste material                                   Additive                               ...
How does it works?  Ceramic        Paste       Additive                                                        Debinding  ...
How does it works?                                Additive  Ceramic  powder            Paste material     Manufactu       ...
How does it works?  Ceramic                      Additive  powder            Paste material                             Ma...
How does it works?  Ceramic                                     Additive  powder                     Paste material       ...
How does it works?    Post- treatment      Post-treatment :       machining       Post HIPing (high pressure and tempera...
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2012 11-08-3 d-printing-event-ceramics

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Transcript of "2012 11-08-3 d-printing-event-ceramics"

  1. 1. Additive Manufacturing Department (ADD) Additive Manufacturing for Ceramic parts ESMA – 8th of Novembre 2012 le centre collectif de l’industrie technologique belge
  2. 2. 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
  3. 3. 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
  4. 4. 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
  5. 5. 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
  6. 6. 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
  7. 7. 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
  8. 8. 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
  9. 9. 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
  10. 10. 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
  11. 11. 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
  12. 12. 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
  13. 13. 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
  14. 14. 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
  15. 15. © sirris 2009 | www.sirris.be | info@sirris.be | 15
  16. 16. 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
  17. 17. 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
  18. 18. 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
  19. 19. 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
  20. 20. 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
  21. 21. 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
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