Ceramics UK 2019 presentation

1. > Precision through quality <
Company profile – INMATEC Technologies GmbH
• Founda(on 1998
• Loca(on Rheinbach, located close to Cologne/Bonn
• Start of produc(on: Jan. 1999
• Core business: Ceramic Feedstock,
Consul(ng/Development CIM-Process
• Employees 60
• Annually cer(fied: ISO 9001:2015
• Client base: worldwide
Founding Member of the
German CIM-Experts Circle

2. > Precision through quality <
Ceramic
Powder
Thermoplas(c
Polymer
Ceramic
Feedstock
Green
Part
Brown
Part
Sintered
Part
Feedstock
Processing
Injec(on
Moulding
De-Binding
Process
Sintering
Process
Ceramic Injec=on Moulding
Ø is an innova(ve technology for the produc(on
of ceramic parts
Ø enables the shaping of 3D-complex geometries
Courtesy: Kläger

3. > Precision through quality <
Ceramic
Powder
Thermoplas(c
Polymer
Ceramic
Feedstock
Green
Part
Brown
Part
Sintered
Part
Feedstock
Processing
Injec(on
Moulding
De-Binding
Process
Sintering
Process
Ceramic Injec=on Moulding
Ø is an innova(ve technology for the produc(on
of ceramic parts
Ø enables the shaping of 3D-complex geometries
Ø needs (almost) no post processing
Ø allows material combina(ons in one step
Wikipedia
Insulatorr
Inner conducter
Semiconducter
Outer conducter

4. > Precision through quality <
Ceramic
Powder
Thermoplas(c
Polymer
Ceramic
Feedstock
Green
Part
Brown
Part
Sintered
Part
Feedstock
Processing
Injec(on
Moulding
De-Binding
Process
Sintering
Process
Ceramic Injec=on Moulding
Ø is an innova(ve technology for the produc(on
of ceramic parts
Ø enables the shaping of 3D-complex geometries
Ø needs (almost) no post processing
Ø allows material combina(ons in one step
Ø is an economic produc(on of high part
numbers

5. > Precision through quality <
CIM as produc=on technique for ceramic parts
Pressing,
Extrusion
Machining
Ceramic Injec(on
Moulding CIM
Slip-Cas(ng
Addi(ve Manufacturing
part number
part complexity

6. > Precision through quality <
Courtesy:
Arburg
Ceramic injec=on moulding
Ceramic
Powder
Thermoplas(c
Polymer
Ceramic
Feedstock
Green
Part
Brown
Part
Sintered
Part
Feedstock
Processing
Injec(on
Moulding
De-Binding
Process
Sintering
Process

7. > Precision through quality <
Ceramic Feedstock…
…is a homogeneous granulate from ceramic powder and thermoplas(c binder for the use in
an injec(on moulding machine or in an extruder.

8. > Precision through quality <
20 years ago
Requirements for CIM-parts:
Wall thickness: 1 – 10 mm
Complexity: moderate
Flow distance: moderate
Ceramic
Powder
Thermoplas(c
Polymer
Ceramic
Feedstock
Green
Part
Brown
Part
Sintered
Part
Feedstock
Processing
Injec(on
Moulding
De-Binding
Process
Sintering
Process

9. > Precision through quality <
Powder availability:
• Powders are produced for the markets Technical
Ceramics and Refractories
• Reasonable priced powders are ceramic materials for
refractories
• Upscale powders are mostly produced as RTP-
powders
20 years ago

10. > Precision through quality <
Availability of thermoplas(c polymers/binder-systems:
• Purchasable on the market: three binder-systems
• Customer proprietary binder-systems
20 years ago

11. > Precision through quality <
Today
Parts:
• Wall thickness: 0.1 – 20 mm
• Complexity: high
• Flow distance: high
Courtesy:Kläger
375 g
110 mm

12. > Precision through quality <
Today
Parts:
• Wall thickness: 0.1 – 20 mm
• Complexity: high
• Flow distance: high
Wikipedia
Courtesy: Kläger
Insulator
Inner conducter
Semiconducter
Outer conducter

13. > Precision through quality <
Courtesy: IKTS
Today
Parts:
• Wall thickness: 0.1 – 20 mm
• Complexity: high
• Flow distance: high

14. > Precision through quality <
Solu(ons for specific applica(ons are required.
The ceramic feedstock shall be fided to the requests of the applica(on.
Today
Parts:
• Wall thickness: 0.1 – 20 mm
• Complexity: high
• Flow distance: high

15. > Precision through quality <
Today
Powder availability:
• Powders are produced for the markets Technical
Ceramics and Refractories
• Reasonable priced powders are ceramic materials for
refractories
• Upscale powders are mostly produced as RTP-
powders
Powder producers understand that a batch selec(on is
mandatory for CIM-applica(ons.

16. > Precision through quality <
Today
Powder availability:
• INMATEC has iden(fied powders, which are suitable
for the CIM resp. the produc(on of CIM-feedstocks.
• It is possible to develop specific powders for defined
applica(ons.

17. > Precision through quality <
Today
Availability of thermoplas(c polymers/binder-systems:
• Purchasable on the market: one binder-system
• Two binder-systems developed by INMATEC

18. > Precision through quality <
INMAFEED Embemould K83, with addi(ves
INMAFLOW INMATEC Binder-system 1
INMAPOM INMATEC Binder-system 2
Today
Ceramic Feedstocks

19. > Precision through quality <
Ceramic Feedstock
Binder systems:
Polymer-Basis: Polyamide-
mixture
Proprietary binder system
Polymer-Basis: Wax-polymer-
mixture
Embemould K83 with addi(ves
Polymer-Basis: Polyacetal
(POM)-mixture
Proprietary binder system
Applica=on-based development of customer specific feedstocks:
Ø Choice of powder and binder-system
Ø Tailor-made binder formula(on
Ø Development on produc(on machines
Ø Produc(on of customer specific feedstock

20. > Precision through quality <
The powder has been processed into feedstock with all
binder-systems
Flow abili=es of Feedstocks based on the different binder systems
ZrO2 3mol% Y2O3
D50: 0.6µm
Density: 6.05g/cm³

21. > Precision through quality <
Flow abili=es of Feedstocks based on the different binder systems
Filling study
Ø Test-mould
Ø Rectangular geometry
Ø Teethed surface
Ø Two cores, not in line
Target
Ø Visualizing the flow behaviour
Stepwise filling of the mould (0.1 cm³ steps)
Ø Focus on: Flowfront joining behind core

22. > Precision through quality <
ZrO2 3mol. % Y2O3
Temperature mould 60 °C
Temperature feedstock 162 °C
Switch over pressure 650 bar
Temperature mould 25 °C
Temperature feedstock 100 °C
Switch over pressure 385 bar
INMAFLOW K2012
Polyamide-basis
INMAFEED K1012
Wax-basis
Flow abili=es of Feedstocks based on the different binder systems
INMAPOM K3012
Polyacetal-basis
Temperature mould 138 °C
Temperature feedstock 175 °C
Switch over pressure 1050 bar

23. > Precision through quality <
Ceramic
Powder
Thermoplas(c
Polymer
Ceramic
Feedstock
Green
Part
Brown
Part
Sintered
Part
Feedstock
Processing
Injec(on
Moulding
De-Binding
Process
Sintering
Process
Courtesy: Desbatec
Courtesy: Binder

24. > Precision through quality <
Proper=es of Feedstocks based on the different binder systems
Ø Wax-polymer-mixture
Ø Moulding temperatures
Feedstock approx.150-160 °C
Mould approx. 50-65 °C
Ø 2-step debinding
Solvent: water
Thermal de-binding
Ø Time need
1. step: (12-) 24 - 144 h
2. step: 35 - 48 h
Ø Polyamide-mixture
Ø Moulding temperatures
Feedstock approx. 110-140°C
Mould approx. 25-35-45 °C
Ø 2-step debinding
Solvent: acetone
Thermal de-binding
Ø Time need
1. step: 18 - 24 - 55 h
2. step: 18 - 22 h
Ø Polyacetal (POM)-mixture
Ø Moulding temperatures
Feedstock approx.170-175 °C
Mould approx. 130-135 °C
Ø Single step debinding
Cataly(c: nitric acid
Ø Time need
single step: 4- 24 h

25. > Precision through quality <
Proper=es of Feedstocks based on the different binder systems
Ø Wax-polymer-mixture
Ø Environmental friendly
Ø 2-step debinding
Ø Established, well-proven
Ø Time need: medium
Ø Polyamide-mixture
Ø Moulding temperatures
Ø 2-step debinding
Ø Low viscosity
Ø Time need: medium to
low
Ø Polyacetal (POM)-mixture
Ø Moulding temperatures
Ø 1-step debinding
Ø High green strength
Ø Time need: low

26. > Precision through quality <
Mould design
What is possible?
Typical values possible
Dimensions diameter < 100 mm bigger
length < 120 mm bigger
Wall thickness min. 0.2 mm
max. 12 mm
Holes diameter > 0.1 mm smaller, down to 0.02 mm
Edges (inner) radius > 0.1 mm
Volume min. 0.01 ccm
max. 50 ccm bigger
Density typically > 99% as wanted, porosity possible
Surface material-specific Ra = 0.4 – 0.6 can be post processed
Tolerances achievable
in general +/- 0.3 %
In par(cular +/- 0.1%

27. > Precision through quality <
Ceramic
Powder
Thermoplas(c
Polymer
Ceramic
Feedstock
Green
Part
Brown
Part
Sintered
Part
Feedstock
Processing
Injec(on
Moulding
De-Binding
Process
Sintering
Process
INMATEC Technologies GmbH – Ceramic Injec=on Moulding
Thank you!