An Industrial Perspective on Additive Manufacturing and Conventional Ceramic Parts Manufacturing Ceramics Expo Plenary Session Track 1 Developing

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Reginald Edwards
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1 An Industrial Perspective on Additive Manufacturing and Conventional Ceramic Parts Manufacturing Ceramics Expo Plenary Session Track 1 Developing Additive Manufacturing Applications for Ceramic Parts I-X Center, Cleveland, Ohio

2 About Since 1982 Mt. Washington Valley New Hampshire, USA 25 employees, 2 plants Near-net shaping and machining of ceramic parts in alumina, etc. Stock ceramic fasteners

3 Vertical integration with conventional ceramic manufacturing 1. Similarities to CIM (Ceramic Injection Molding) 2. Quality of parts how 3D printed parts compare in quality and other technical concerns 3. Mass production experience going beyond sample/prototype quantity level 4. Variety of applications explored

Similarities to CIM on the one hand Green AM parts are fired after forming,

are virtually identical Fired densities are the same, theoretical density is

9g/cm 3 Similar design considerations exist for good production yield, such

4 Similarities to CIM on the one hand Green AM parts are fired after forming, just like CIM parts (with exception to SLS) As-fired tolerances achievable are virtually identical Fired densities are the same, theoretical density is not common to parts manufacturers. e.g. 99% Al 2 O 3 = 3.9g/cm 3 Similar design considerations exist for good production yield, such as adding corner radii Process limitations such as wall thickness 4mm Both are temperamental processes!

5 CIM Tooling Made in-house or out of house, it s additional leadtime and expense Engineering intensive Material dependent Cost ranges from $300 to $30,000

6 Plastics, metals, and now ceramics Ceramco materials A998 (99.8% Al 2 O 3 ) YTZP (3 mol % Yttria zirconia) Lithoz CeraFab materials HP 500 (99.9% Al 2 O 3 ) 3Y 610 (3 mol % Yttria zirconia) Like plastic molders, customers can have a sample/prototype 3D printed and for production same/comparable materials are available

layers, support structures, & slurry Sintered parts

7 Part design and process is critical Green parts (before firing) Parts are prepared by removal of backlight layers, support structures, & slurry Sintered parts (post firing) Very long thermal cycle, watch for delamination!

On the other hand, AM has Designs that can only be made by AM Need for support structures, and not being able to recycle them like CIM feedstock Preparation of

8 On the other hand, AM has Designs that can only be made by AM Need for support structures, and not being able to recycle them like CIM feedstock Preparation of AM parts for firing requires labor in any case (CIM not always) Strength of lithography layers Scalability and cost, CIM is more economical for higher volume still

Physical/Mechanical Properties Layers in the X-Y orientation Alumina (HP 500) test bars with layers in the plane of the sample have comparable 4-point bend strength

9 Physical/Mechanical Properties Layers in the X-Y orientation Alumina (HP 500) test bars with layers in the plane of the sample have comparable 4-point bend strength (4PB) to the same bars made in CIM alumina Layers in the Z direction The same test bar with layers normal (perpendicular) to long axis do not have good 4PB strength

Mass Production Experiences Case Study: Simple thin washer in alumina Conventional process would be micro-cim but the quantity was 1,000 pieces Very

10 Mass Production Experiences Case Study: Simple thin washer in alumina Conventional process would be micro-cim but the quantity was 1,000 pieces Very high precision tolerances and quality requirements Removal of backlight layer challenging and affecting quality Very small part, able to make many at once

Mass Production Strengths Tool free manufacturing Many parts can be made simultaneously (small parts) Automated (unattended) operation Cycle times can be improved

11 Mass Production Strengths Tool free manufacturing Many parts can be made simultaneously (small parts) Automated (unattended) operation Cycle times can be improved upon with settings Weaknesses Labor is not eliminated Backlight layers Support structures Slurry cleaning Software limitations: error alarms? run losses Material cost 100X

12 Applications

13 Parts for Highspeed Jig 2 parts have a 0.4mm feature which is critical, so very tight tolerance (0.4+/- 0.05mm) and the other has a 0.45mm slot which is mm Customer wanted qty 10 of each in alumina

14 MIT Nozzles Material: Zirconia Many different configurations in the program Internal features, such as fine holes O-ring seal required additive manufacturing married with subtractive manufacturing

15 Material: Zirconia Audio Earphone Has truncating ID holes, impossible to machine or mold with tooling Cost very high compared with competing plastic parts (also 3D printed)

16 Needle Puller Material: Zirconia Collet design for hypodermic needles High volume, 10k & 100k Watch the step transition!

17 Filter/Sponge Material: Alumina Too large to make in one piece Organized/repeating structure would not be possible to manufacture any other way

18 Simple Bushing Material: Alumina Low volume, fast lead time Cost comparable to machining and not any faster

19 Wire Guide Material: Zirconia Very critical transition area & must be very flat Wear application, medical, replacing stainless steel 4mm thickness, too thick?! = watch for cracks

20 Quartz Tube Material: Alumina Replacing a machined quartz product Very intricate helix on OD Placement of parts for production of two products in the same run

Thank You! Questions? Thomas Henriksen t.

21 Thank You! Questions? Thomas Henriksen

Micro CIM for Precision Instruments and Medical Applications. SmartManufacturingSeries.com

Micro CIM for Precision Instruments and Medical Applications SmartManufacturingSeries.com Outline Discussion of micro-scale ceramic injection molding experience Introduction to CIM Case Studies Conclusions