Guillaume de Calan

WEBINAR

Ceramic additive

manufacturing by FDM

process

I- CORPORATE

CORPORATE3

New material development

Customer centered R&D

3D printing materials

Focused on innovation

Ceramic powder production

Alumina, Zirconia, ZTA/ATZ, Yttria

Batches > 1 T

Ready to use materials

Industrial SME

OUR CUSTOMER PROCESSES

Pressing Injection moldingCasting 3D printing

Sintering

(1400 – 1800°C)

OUR APPLICATIONS5

Semiconductors

Fluid Handling

Jewelery and watch

making

AerospaceBiomedical

Wear parts and

tooling

II - 3D PRINTING

Powder + binders

High volumic loading

Controlled rheology

Extrusion

Extrusion temperature

Cooling

± 5% diameter

1 2

CompoundingNANOE ‘S CORE

COMPETENCIES

8

Blend of powder (> 50 vol%) and

several binders (backbone,

soluble phase, plastifier, tackifier,

dispersant...) at melting

temperature

NANOE ‘S CORE COMPETENCIESS

Compounding of

CIM/MIM feedtsock. Extrusion

of highly loaded sinterable

filaments

alumina,

white zirconia,

black zirconia,

316L

9Zetamix process

Post

processing

Rotary tumbling

Polishing

Sintering

Thermal Debinding

Shrinkage

Final part

Final density

Mecanical properties

4 5

Shape and precision

Surface finish

Green density

File

preparation

Chemical debinding

Drying

Debinding

32 61

Printing

File preparation

10FILE PREPARATION 1

11FILE PREPARATION 1

Support material

spool

Build

material spool

Extrusion

heads

Part support

structure

Build platform

Built part

12FDM/FFF 3D printing2

13DEBINDING3

14

After Debinding Dense ceramic

Densification

• Typically density after sintering: 99% for

ceramic, 90 to 95% for metals

• Going from 50 – 60 % density to 90 – 99%

density implies a linear shrinkage of 15 –

20%

SINTERING4

1515

Key benefits of Zetamix

Accuracy after

sintering is +- 0.1mm

(for parts up to

80mm)

Possibility to print

closed porosities

and hollow

structures

Training time is 1 day

before you print good

parts

Can be used by any

trained technician

Very little QSE issues

(no volatile powders or

toxic materials)

Easy-to-use System Investment cost

are low

Optimized two head 3d

printer, debinding kit

and atmosphere

furnace

Starting, training and

user guideline for each

material are provided

Compatible with a wide

range of materials

currently available

(Alumina, zirconia,

black zirconia, stainless

steel) and in

development (SiC, WC-

Co, Si3N4…)

Compatible with a wide

range of materials

currently available

(Alumina, zirconia, black

zirconia, stainless steel)

and in development (SiC,

WC-Co, Si3N4…)

Versatility Good accuracy

16

BINDER JETTING INKJET SLA FDM

Price

Precision

Dense

Speed

100 µm 50 µm10 µm 100 µm

Benchmark

17

Heat and wear resistant tooling

Complex ceramic parts for

high temperature applications

Prototyping

General tooling

applications

Ceramic Metal

Typical applications

III- USE CASES

Use case 1: sample environment

19

• High temperature environment for

XRD analysis

• Sample holder, heating element

holders, gaz blowers...

• Several on demand parts,

sometime complex parts, in low

volume (1 – 5 units), urgent

requirements

Customer need

20

• Custom made heating cartridge

• Sample holder made as

replacement of stainless steel

parts (lower heat conductivity)

• Futur projects: water cooled micro

furnace

Zetamix use cases

Use case 1: sample environment

21

• Custom sizes and shape for each

experiment

• Cost savings (5 € / printed cartridge vs 50

- 200€ for commercial versions)

Heating cartridge• High temperature resistance, low heat

conductivity compared to stainless

steel

• Speed: replacement part was printed

and sintered in 1,5 day

Sample holders

Use case 1: sample environment

Use case 2: custom impellers

22

Ink preparation industry

• Need for custom made impellers

with specific shape and size

• Need to avoid tool wear and

oxydation, and product pollutions

• Part replacement need to be fast

Customer need

23

• Printing of custom made impellers with

specific size and shape

• Zirconia is wear and corrosion resistant

• Savings on cost and time (1 week, 12€ in

material cost compared to 6 weeks and

300 - 1000€ for a custom made impeller)

Zetamix use case

Use case 2: custom impellers

Use case 3: high temp probe

24

• End users in aerospace applications

• Need for high temperature flow

sensors

• Parts impossible to manufacture

by traditional ceramic processes

Customer need

25Use case 3:high temp probe

26

• Printing of pressure sensors with

internal channels

• Alumina can withstand up to 1800°C

• Possibility to make more complex

parts with multiple holes and

channels

• Possibility to add cooling/heating

circuit

Zetamix use case

Use case 3:high temp probe

Use case 4: watch prototyping

• Produce ceramic pieces by uniaxial

pressing or injection molding

• Cost for a new mold for ceramic

injection molding: 5 – 20 k€

• Need for prototyping methods for

new designs

Customer need

28

• Printing of new designs for watch

and jewelery

• Black and white zirconia

• Need some additional step of

finishing

• Allows to iterate quickly and validate

designs before going to full scale

production

Zetamix use case

Use case 4:watch prototyping