Walter kuhn maxon ceramics

Smart solutions for driving systems
Walter Kuhn
maxon motor GmbH, July 11, 2019

maxon motor GmbH
− founded 1989
− 500 employees
− 4800m² production area
− 45 employees in the ceramic
department
2
Location for development and production of
gear drives and ceramic.
© maxon motor GmbH, July 11, 2019

Standard-
and
specialgears
Electronic and
drives
Injection molding
plastic
ceramic
metal
Machining of
metal and
ceramic
EncoderEC and DC
motors
technological competence

Ceramic Injection Moulding (CIM)

CIM production process

Binder system + ceramic or metal powder
CIM
• ZrO2
• Al2O3
MIM
• 17-4PH, stainless steel (martensitic)
• 316L, stainless steel (austenitic)
• 42 CrMo 4 (heat treatable)
• FN 02 (magnetically soft)
Feedstock, the basic material

− CIM = Ceramic Injection Moulding
− MIM = Metal Injection Moulding
Conventional Injection Moulding

There are different feedstocks for CIM and MIM on the market. Depending on the application, different
binder systems of the feedstock have different advantages. Debinding by acid, heat or solvent, we have
all the equipment to use the perfect feedstock for your application.
Acid Heat Organic solvent
Debinding

− Debinding furnace
− Control of the debinding process by lost of weight
− The green part will be transformed into a brown part
− The process is limited by the thickness of the part
− (CIM about 3mm; MIM about 5mm)
Debinding oven

− By sintering the parts reach their full density and hardness
− The shrinkage is about 20% (MIM) to 30% (CIM)
Sintering furnace

CIM products and applications

Ceramic axes improve the performance of our motors and gearboxes signifficantly.
We optimized the production of these parts and offer you to participate in our
experience.
We are specialists for driven systems, also in ceramic
Configurator

Steel axes
GP22A
520h/1Nm
Ceramic axes
GP22C
2500h/1,8Nm
Wear resistent axes in maxon gearheads

Small linear guide unit (13x13x35 mm)
13
Two Ø2 ceramic rods
ceramic spindle
M2-4h
− Excellent wear resistance
− Insignificant slip stick effect
− Grinded, precise thread, M2-4H
− Very small overall dimension

Small linear guides by modular system

Small ceramic parts ensure high precision

− Up to 100 times longer lifetime
− Excellent anti-friction property
− Totally non-magnetic
− Typical applications:
− electrical and optical devices
− Vacuum technology
− medical devices
Ceramic spindles

Using CIM,
- parts can be complex and tiny
- parts are extremely hard
- parts work reliable under harsh conditions
maxon hi-tech CIM components
We are specialists in CIM, how can we support your business by ceramic?

− Totally nonmagnetic
− Extremely wear resistant
− Complex shape by CIM
− Typical applications:
− gear parts
Watch parts

− Extraordinary wear resistance of ceramic
− Working in harsh enviroments: high
temperature, chemical attack, strong magnetic
field…
Typical applications: nozzles, housings, pins….
Industrial applications

polished housing made of black ZrO2
• Scratch resistance
• Brillant surface
• Complex shape by CIM
• Add colurant to black finish
Typical applications:
• consumer applications

− Hardness 1350 HV
− Bending strength > 800 N/mm2
− Elasticity modulus 2 x 105 N/mm2
− Heat expansion coefficient 10 x 10 -6 1/K
− Electrical resistance 108 ohm
− Extremely wear resistant
− Excellent anti-friction properties
− High temperature stability
− Excellent insulation against heat and electricity
− Similar properties to steel expansion rate and Young’s modulus
− Plasticity – non existent
− Non-magnetic
− Bio compatible
− To consider tungsten or PEEK, don’t forget ZrO2!
Zirconia Oxide - a versatile material

− Wall thickness should be less 3mm
− Accuracy about general tolerance DIN 2768 m
− Radiuses about 0.1mm are helpful
− Prefer compression load
CIM component design

CIM component design

Tolerances
− 1% of nominal dimension can be achieved
without additional work, typically ( 0.02 – 0.2)
− Parts can be machined in the green state or
moulded, dependent on volume
− Fine tolerances can be ground using diamond
wheels
CIM accuracy and machining

− Tool: 0 €
Approximately 70 € at 10 pcs/order
Process steps: extruding, debinding/sintering,
2 grinding processes, polishing
They are extruded, simpler and less expensive
Applies to many round bodies
− Tool: 20,000 € (including screw)
Approximately 12 € at 2,500 pcs/order
Process steps: moulding, debinding/sintering, fit grinding
− Tool: 20,000 €
Approximately 2,50 € at 80,000 pcs/y
Process steps: moulding, debinding/sintering
Commercial aspects: price examples

Metal Injection Moulding (MIM)

Why MIM technology?
The parts require high precision
− the parts are produced in high quantities
(batch sizes over 1000 parts are the rule)
− MIM components can replace assemblies
− the parts can have a complex shape

MIM materials
− Nearly all steels
Typical steels for MIM parts are:
− 17–4PH, stainless steel (martensitic)
− 316L, stainless steel (austenitic)
− 42 CrMo 4 (heat treatable)
− FN 02 (magnetically soft)

Planetary carrier traditionally
made of 5 parts
Using MIM-technology
-> one-piece
− Reduced assembly
− Planetary carrier
MIM components application
also possible in CIM-
technology

− The electronic of the sensor barrier is
protected by a small housing Ø20 x 20
made of stainless steel
− To reach the required accuracy of the
complex shape, the housing is produced by
MIM
Ø20
20
Small things makes the world better

We build more
than motors
Drives. Systems. Mechatronics.
Something you need to drive? We’re here to help.
No matter how specific your requirements may be.

Walter kuhn maxon ceramics

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