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Stc overview (pre brd)
1. Superior Technical CeramicsSuperior Technical Ceramics
St. Albans, VermontSt. Albans, Vermont
A WORLD LEADER IN ADVANCEDA WORLD LEADER IN ADVANCED
MATERIALS SOLUTIONSMATERIALS SOLUTIONS
2. Vital Statistics
BUSINESS: Ceramic material technology with complex forming and
machining capabilities to manufacture technical ceramic components
and assemblies.
EMPLOYEES: Approximately 130
AGE: 113 years old
SIZE: 135,000 ft2 in St. Albans location – two buildings
OWNERSHIP: Privately held – American owned and operated
Location: St. Albans, VT – headquarters and primary manufacturing
Partners: INTA Technologies - Santa Clara, CA –– plating / metalizing,
brazed assemblies
Anderman Ceramics Ltd.- Supplier of Industrial Ceramics
3. STC at a Glance…STC at a Glance…
• SuperiorTechnical Ceramics has beenproducingceramics forSuperiorTechnical Ceramics has beenproducingceramics for
113years113years
• In1975, thebusiness movedfromNew York/New JerseytoitsIn1975, thebusiness movedfromNew York/New Jerseytoits
current locationintheSaint Albans IndustrialParkcurrent locationintheSaint Albans IndustrialPark
• Thetwo facilities inSt. Albans haveapproximately135,000Thetwo facilities inSt. Albans haveapproximately135,000
squarefeet of manufacturing, warehouse, andofficespacesquarefeet of manufacturing, warehouse, andofficespace
• STC expands its capabilities bycontinuallyre-investinginnewSTC expands its capabilities bycontinuallyre-investinginnew
machinery, labequipment, andtechnologymachinery, labequipment, andtechnology
5. Company DirectionCompany Direction
• Tomaintainahighlevel of customersatisfactionthroughTomaintainahighlevel of customersatisfactionthrough
thecontinuedexcellenceof quality, ontimedelivery, andthecontinuedexcellenceof quality, ontimedelivery, and
exceptionalCustomerService.exceptionalCustomerService.
• Toinsurethat Superior’s TechnicalSales ForceandinToinsurethat Superior’s TechnicalSales Forceandin
houseEngineeringForceis interfacingwithcurrent andhouseEngineeringForceis interfacingwithcurrent and
perspectivecustomers toperspectivecustomers to
• ResolvedesignandcostingissuesResolvedesignandcostingissues
•Considerform, fit andfunctionalcriteriaareutilizedConsiderform, fit andfunctionalcriteriaareutilized
withaneyeonmanufacturingwithaneyeonmanufacturing
•Minimizecost of ownershipMinimizecost of ownership
6. Diverse Engineering StaffDiverse Engineering Staff
• Designing and processing
ceramics are different than metals
or plastics.
• Our team of engineers consists of:
• Ceramic Engineers
• Mechanical Engineers
• Materials Scientists
• Material property analysis
• Product development
• Failure analysis
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7. • Aviation & Military
• Semiconductor
• Telecommunications
• Pumps and Valves
• Medical
• Lamps/Lighting
• Electro-Optics
• Plasma Cutting
• Industrial Ignition
• Textile/ Wire Feed
• Laser Systems
• Refractories
• Nuclear
• Appliance Insulators
• Electrical Feed thru
• Scientific Instruments
• Water Treatment
• X-Ray Systems
• Mass Spectroscopy
• Conveyor Systems
Markets ServedMarkets Served
www.superiortechceramics.com
9. Manufacturing ProcessManufacturing Process
I s o s t a t i c P r e s s i n g
D ia m o n d G r i n d in g
In s p e c t & S h ip
C o a t in g s A s s e m b l y
F i r i n g
G r e e n M a c h i n i n g
E x t r u s i o n D r y P r e s s i n g
R a w M a t e r i a ls M ix e d & B a t c h e d
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11. Forming Methods: OverviewForming Methods: Overview
STC manufactures
from prototype to
large volume
orders.
Which forming
method is chosen
depends upon cost
effectiveness.
www.superiortechceramics.com
Extrusion
Cold Isostatic
Pressing
Dry Pressing
12. Blank Forming: ExtrusionBlank Forming: Extrusion
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Pan mixed material is loaded
then extruded or “squeezed”
out of a metal die to form
rods.
Pressures in excess of 200
tons are often required for this
process.
13. Blank Forming: IsopressingBlank Forming: Isopressing
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Dry bag isopressing
is used for high
volume production
Wet bag isopressing
is done in a chamber
press
14. Part Forming: Dry PressingPart Forming: Dry Pressing
Uniaxial dry pressing involves
applying pressure from top and
bottom punches.
Often only large volume
orders are dry pressed because
of tooling requirements.
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16. FiringFiring
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• Firing, also known as sintering, is
the process used to densify the
ceramic to achieve optimal
properties .
• Depending on the ceramic
composition – also known as a
“body” – temperatures for
densification can be as high as
3100o
F (1700o
C)!
17. Shrinkage During FiringShrinkage During Firing
• Ceramic components can
shrink from 15-25%
during the firing
process!
• Shrinkage is accounted
for in green forming and
machining to yield a
near net shape after
firing.
• Typical “as fired”
tolerances are +/- 1% or
+/-0.005” whichever is
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18. Designing for Ceramic MfgDesigning for Ceramic Mfg
Typical “as fired” tolerances:
• +/- 1% or +/-0.005” whichever is bigger
• 0.006”/inch max camber allowance
• Wall thicknesses of 1/16”min – (geometry dependant)
• Fillets and edgebreaks - .025”max R or ch
• 63 microinch surface finish
28. Superior Technical CeramicsSuperior Technical Ceramics
Thank you for your time
This concludes the presentation
www.superiortechceramics.com
Editor's Notes
STC began in New York/ New Jersey. The plant was the first building in the St. Albans Industrial park in 1974, it was commissioned in 1975. 80,000 square feet of production and office space. There have been 4 expansions.
STC 2, located across the street in the Industrial Park, has 55,000 sq ft of manufacturing space.
Ceramics are used in a variety of markets. STC has a diverse customer base.
STC is one of a few companies in the US with rights to import Lava. Grade A lava only comes from one place on Earth -- South Africa.
This is an overview of the major manufacturing steps that STC takes in order to make products. Emphasize the variety of forming methods & expertise in green machining.
ST purchases over 75 different Raw materials. Every material has to pass our Raw Materials Qualification (RMQ) testing in order to be used for production. This testing is conducted in house by our lab. Raw materials are qualified before use in wet mixes or spray dried powders. All batched materials are tested again for quality and processing characteristics Specific surface area analyzer & Laser Particle size analyzers characterize the powders before compaction. Pill pressing and test fires determine shrinkages of powder, density, and other properties of final product Dry pressing and iso-pressing require powder feedstock that has been ball milled and spray dried Each forming method requires different organic additives in order to form green blanks. The raw materials are mixed with binders and plasticizers in a ball mill or pan mixer
Quantities and geometries dictate the forming method used. Each method has advantages and disadvantages depending on cost and volume. An advantage of STC is the ability to mix and match forming and finishing processes based upon geometry and volume.
Wet-bag isopressing is for low run, large, or custom jobs. Dry-bag isopressing is for high volume jobs.
CNC equipment is also a more repeatable process than non-CNC equipment. STC will use both methods depending on volume or delivery timelines. Dust collection is an important aspect of green machining. The part is in a chalk-like state that can be turned, milled, and ground with conventional tooling. Material removal rate is 10 times greater than when the part is fired.
STC has small and large kilns. Kiln cycles can last from one day to a week or more. Both gas and electric kilns are used.
Smaller kilns are used for specialty firing cycles. Small orders are also fired in order to meet delivery dates. Testing is usually done in small kilns as well.
Glazing is done in order to keep the ceramic clean. Electrical properties of glazed products are sometimes tested. Other coatings can be applied to ceramics as well. Glaze can be formulated to accommodate application use temperatures. Hi-temp 2500F, standard 2300 F and low temp ~1800 F glaze is available.
Diamond grinding is necessary because as parts shrink in the kiln they distort.
