Lower costs for the production of individual parts and small quantities are mentioned as one advantage of additive manufacturing. In this paper it is investigated under which conditions additively manufactured components are cheaper or more expensive than conventionally manufactured components. For this purpose, two different components with two different manufacturing processes, CNC machining and Vat photopolymerization, are examined for their economic efficiency with respect to the parameters manufacturing time, manufacturing costs and material efficiency. The results show that the advantages of additive manufacturing are fully exploited when components are designed efficiently and in a complex way.
Additive manufacturing with plastics and metals is opening up more and more areas of application and has now achieved a high degree of public awareness. On the other hand, the process possibilities of ceramics only seem to take place in very close circles. Ceramic materials rarely appear in public perception – apart from porcelain, sanitary ceramics or tiles – but they are of great importance in almost all technical processes.
Additive manufacturing has developed rapidly in recent years and is now used in many industries. In June last year, WZR ceramic solutions hosted a conference on the possible applications of this technology especially in the ceramics industry. Top-class speakers ensured a full auditorium. The event dealt not only with the additive processes, but also with the upstream and downstream processes as well as with legal questions and aspects of occupational safety.
Author: W. Kollenberg, WZR ceramic solutions GmbH, Rheinbach
Conference Material Testing 2016
1. and 2. December 2016
TECHNICAL CERAMIC MATERIALS
Author: Dr. Wolfgang Kollenberg
Published by PROF. DR. JOCHEN KRIEGESMANN
8 Volumes, ca. 9000 Pages, A5 format,
6 updates per year
The first contact between the laboratory Junglas and the company WZR in 2011 was very promising: The company owner Ztm. Joachim Junglas and Dr. Wolfgang Kollenberg exchanged views on development issues and discovered common perspectives. This first meeting resulted in a close cooperation.
Reactions between molten metal, slag and refractory material cause corrosion of the refractory material and thus to premature wear and failure of the liner. For the endurance of refractory materials corrosion is a determining factor. In order to minimize the costs involved, it is important to know the individual factors of corrosion (temperature, pressure, oxygen activity, flow and density of the melt, phase composition, particle size, pore, grain formation of the material) and to quantify them if possible. However, since some parameters are determined by the casting process itself (melting temperature of the metal), the selection of parameters to be varied is limited. Slag and refractory material must be matched to the melt. Experience shows that not the melt but more often the slag leads to the wear of the lining.
Sintering trays for dental applications Digital Dental Magazine redaction 1 2015 – digital dental magazin Ausgabe 1 2015
Our sintering trays are made of aluminum oxide ( > 99 % Al2O3) and are suitable for high temperature applications up to 1500 ° C . Due to the high porosity of the material , the thermal shock resistance is excellent. It is very easy to vary the trays in shape and size due to the 3D printing process so we can probably find a tailored solution for your demand. Since the trays are directly constructed from CAD data, small quantities , different component variants or individual labels are realizable without much extra effort. We offer individual labels and geometries for orders of at least 10 sintering trays; prices and delivery times for those are different depending on the requirements and will be calculated on demand.
Additive Manufacturing becomes more and more important to ceramic industry. For industrial production Lithography and 3D-Printing are available today. Additive Manufacturing is cost-effective, if only small numbers of components are needed. Expenses for molds are saved, storage of molds is not necessary and customers can be served quicker and much more flexible. Any change in design can be realized on short call. The term “series production” becomes a new meaning with Additive Manufacturing. Here it is not necessary to produce a large number of equal components, to reduce costs. Different parts can be produced in one batch, coming to “series production of single parts”.
Additive Manufacturing currently arouses great interest. The Laser sintering of metals is almost ready to be used in the industrial mass production. Stereolithography is already used for the production of ceramic components and is a possible precursor for injection molding. 3D printing for example is used for the production of adapted firing auxiliaries, bone replacement or design objects. The benefit of additive methods is the material efficiency:
Using the method of 3D printing makes it possible to reuse the non-moistened powder fractions without any loss. Using FDM or 3D can produce ceramic shapes made for CNC machining. The multi-material 3D printing opens up completely new areas of application, since the properties and the color of a component can be changed locally. It is feasible to produce dense microstructures by using particle filled inks. Fabric reinforcements and functionalization can be realized by printing with several filled particle-inks. In order to provide users with a long-term perspective, WZR works closely with cooperation partners to establish 3D printing as an industrial scale production process for ceramic components.