additive manufacturing of ceramics - 3d printing · pdf fileadditive manufacturing of ceramics...

ADMATEC EUROPE BV

3D Printing Materials Conference

Jaco Saurwalt Director ECN Environment & Energy Engineering Co-founder Admatec

Michiel de Bruijcker Managing Director Admatec

Additive Manufacturing of Ceramics

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›› Introduction

›› Founded in November 2013 ›› Spin-off from Formatec Ceramics ›› 5 employees ›› Ambitious technology roadmap

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›› Introduction Admatec delivers printed components produced by Additive Manufacturing technologies. Components should be 100% functional with great mechanical properties and low surface roughness. Admatec aims to operate with in in-house developed technology in order to guarantee innovations and total independency .

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›› Introduction

Shareholders

ECN Formatec

Budget 2014

Revenues

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›› Market attention

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blending

compaction

sintering

• Particle size, distribution, shape

• Impurities • Homogeneity • Stability • Strength green product • Sintering dopes • Sintering ambient, Temp • Density / porosity • Strength • Hardness • De-gassing

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›› Powder Metallurgy (PM) basic process

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›› ADMAFLEX TECHNOLOGY

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›› Advantage Powder Metallurgy

›› Free Shaping, avoid machining

›› Isotropic properties and microstructure

›› Ultra high purity materials

›› Flexibility by unique alloying/doping

›› Less energy consumption, less loss of material, less process

steps

›› Disadvantage Powder Metallurgy

›› Sintering step

›› Shrinkage

›› Deformation / Creep during sintering

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›› Technology

Material Recipe development

Machine Concept, Construction, Realisation Software

Process

Qualification, Validation, Characterisation

In-house development

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›› ADMAFLEX TECHNOLOGY

Resolution µm 40

Layer thickness µm 25 100

Speed mm/h 4 – 5 >10

Size building platform mm 80 x 80 x 150

Materials - Alumina oxide / Zircon oxide

Density % >98%

The ADMAFLEX technology delivers complete dense microstructures with low surface roughness's. Similar material properties as products shaped by traditional technologies.

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›› Admatec & market

Test & prototype

Alternative to grinding

Alternative to injection moulding

Design requires additive manufacturing

Based on paying customers

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›› Application: Endoscopy

Need for more complex ceramic parts

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›› Application: Endoscopy

Request for printing study:

1, 5, 10 pcs Details of 0.3 mm Pull force of 4N on bridge

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›› Application: Endoscopy

Cross section of the request part in the final assembly

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›› Re-design to enable additive manufacturing

Fixing the ‘floating ’ axes. - Support structure - Adding a radius

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›› Application: Endoscopy

Determination of print direction

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›› Application: Endoscopy

First print results

Additional radius Missing hole

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›› Application: Endoscopy

Final print results

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›› Application: Endoscopy

The business case: Pieces per printing 48 (can be optimized) Printing time < 1hr Breakeven point with injection moulding is beyond 15.000pcs per year. Small and high complex parts pushes the injection moulding technology. Printing will be a production technology in these cases.

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›› Application: Filter

H = 54.2 mm Ø = 42.57 mm. Split opening of 0.2 mm Can you print discs?

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›› Application: Filter

Engineering a full ceramic filter, demonstrating the customer what the full possibilities of printing ceramics are.

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›› Application: Filter

Printing results

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›› Application: Endoscopy

The business case: Added value by printing functional integrated filter element. Elimination of assembly parts. Breakeven point unknown also because parts are not to be produced with any other techniques.

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›› Conclusion

Printed ceramic parts find its way to new ceramic components and rapidly defines new borders for production solutions.

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›› Technology roadmap

2014 2015 2016+

Ceramics ZrO (black) SiC/SiSiC Si3N4

Sizes [mm] 300 x 300 750 x 750

Metals 316L Ti W Mo

Low surface roughness, high density, high accuracy

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First results:

Printed body of several hundreds of layers

›› Microstructure of printer 316L stainless steel

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ADMATEC EUROPE BV

Thank you for your attention

info@admatec.nl