Kyocera thus expands its portfolio in the field of technical high-performance ceramics and creates new opportunities for the production of complex, highly stressed components.
"The introduction of additive manufacturing is a milestone for our company," says Dr. Carsten Rußner, Managing Director of KYOCERA Fineceramics Europe GmbH. "It opens up new potentials for development and application as well as for strategic positioning in the market."
3D Printing of Components Made from SiSiC
Silicon-infiltrated silicon carbide (SiSiC) is one of the ceramic high-performance materials and impresses with extraordinary mechanical strength, thermal stability, rigidity, and high wear resistance. Particularly due to its nearly measurable thermal expansion, SiSiC is ideally suited for demanding applications such as aerospace, the semiconductor industry, or industrial manufacturing.
Kyocera independently prepares both StarCeram Si used for conventional processes and StarCeram AM-Si developed for 3D printing – both materials exhibit comparable material properties.
With the advancement of additive manufacturing technologies, 3D printing has proven to be a forward-looking method for producing complex SiSiC components. Compared to traditional shaping processes such as isostatic pressing, slip casting, or film casting, additive manufacturing offers significantly greater design freedom and shortened development cycles. For example, topology-optimized components can be produced, leading to significant weight reduction.
Ceramic 3D printing thus offers the ideal solution for demanding constructions where conventional techniques reach their limits. Thanks to this process, Kyocera offers its customers a wide portfolio of durable, robust, and precise components, from prototype development to series production. The process is typically based on a two-step procedure: First, a green body is created from silicon carbide powder and polymer binder using the binder jetting process. This is then infiltrated with molten silicon, which reacts with the remaining carbon to form the final SiSiC structure.
"This progress is the result of intensive research and development work," explains Sarah Diener, Team Leader for Additive Manufacturing. "We look forward to creating added value for our customers by producing complex component geometries."
The advantages of additively manufactured components made from technical ceramics
Complex Geometries
Additive manufacturing enables the realization of highly complex geometries that cannot be achieved with conventional methods. This includes, among other things, curved structures, undercuts, and bionic structures. The more complex the geometry, the more the advantages of the process become apparent.
Design Consulting
For the optimization of component geometries and the implementation of topology-optimized structures, Kyocera offers comprehensive design consulting. Through this, the component weight can be reduced or the performance of the components increased in dialogue with the customer. Thanks to close cooperation with the company's own design center, tailored solutions are created that are optimally aligned with the respective application.
"Additive manufacturing enables us to respond flexibly to dynamic market demands," emphasizes Dr. Nikolaos Katsikis, Director of Research & Development. "Especially for large and complex components, we see a high added value for our customers – particularly when we are allowed to support optimization through our design consulting."
Process Expertise
With many years of experience in the field of technical ceramics, Kyocera offers not only homogeneous, highly pure materials but also demanding post-processing and coating technologies that significantly expand the application range of 3D-printed components. In particular, the Selb location stands out as a comprehensive manufacturer of SiSiC components and specializes in furnace technology for large-volume components, the finishing of the material, as well as joining experience and coating technologies.
Short Production Time
The multi-stage manufacturing process has been specifically developed for large-volume and complex components. The maximum component size is 325 x 270 x 130 mm with wall thicknesses starting from 3 mm. By eliminating green machining, extensive programming times, and the production of tools for machining, particularly short production times and the manufacturing of larger quantities are possible.
With the successful implementation of this technology, Kyocera underscores its claim to innovation and offers future-proof solutions. The new possibilities not only strengthen competitiveness but also solidify the role of the Selb location as a leading center for ceramic manufacturing technology within the Kyocera Group.
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