Ceramic Forming Capabilites

Customized components with an optimal price-performance ratio



The selection of the appropriate ceramic molding process depends on the desired end properties, geometry, and size of the components to be manufactured. The number of pieces, raw material input, and process costs additionally determine which process is most economical.

Die Casting

This molding process involves pouring a ceramic slip under pressure into a microporous mold. Compared to traditional slip casting, the time-consuming re-drying of the plaster molds is eliminated. In addition, the green body is produced in a few minutes instead of several hours. The molds are slightly more expensive than those used for slip casting and are therefore well suited for medium to large series. This molding process is therefore particularly suitable for the series production of plate-shaped components. Die-cast products from Schunk offer very high repeatability in relation to the geometry of the bodies and extremely homogeneous material properties, which are highly appreciated by our customers. Combined with 3D-supported 100% control, we offer the highest degree of consistency and precision.

Slip Casting

In ceramic slip casting, a ceramic slip is poured into porous, absorbent plaster molds. The preferred method is hollow casting, in which the inner contour of the blank follows the outer contour. In this process, the aqueous suspension of the ceramic slip is drained through the plaster mold. After reaching the defined wall thickness, the excess slip is poured out. The process is suitable for the production of rotationally symmetrical bodies of low wall thickness, such as pipes. However, large plate geometries or geometrically complicated components are also possible. At Schunk Ceramics, it is possible to produce:

  • rotationally symmetrical components up to 4 m in length and 300 mm in diameter and more
  • plates up to 1.0 m x 0.8 m
  • complex components

Large quantity production is easily realized using slip casting.

Dry Pressing

Uniaxial dry pressing enables dimensionally accurate mass-produced articles to be molded. In this process, a free-flowing granulate is compacted in steel dies which are machined according to the component to be produced. Dry pressing is the most economical process for high volumes and is suitable for simple to less complex geometries.

Isostatic pressing

This molding process enables the production of uniformly compacted blanks and large bodies by means of an elastic mold in which a green compact is produced by a pressure vessel filled with liquid. This green compact is then machined to the final shape required by the drawing in various downstream production steps. Isostatic pressing is suitable both for prototypes and for the series production of large complex components. Dimensions of 1.0 m x 0.8 m are possible.

Extrusion

The extrusion process (plastic forming) is carried out by means of vacuum screw or piston extrusion. In this process, a homogenized compound including plasticizer is formed into continuous strands by a die. Optimum compaction and venting of the extruded mass is an essential prerequisite. Depending on the design of the die, complicated profiles up to a length of 4 m can be produced in addition to rotationally symmetrical components. Profiles and rolls from Schunk are characterized by extremely low deflection (up to a TIR < 3 mm) and generally high dimensional accuracy.

3D printing with IntrinSiC®

3D printing as an innovative shaping method

IntrinSiC®, the new 3D printing process from Schunk Technical Ceramics, is used to additively manufacture ceramic components in even more complex shapes, high quality, and numerous sizes. The new manufacturing process is particularly interesting for manufacturers who do not want to forego the usual high stiffness and strength of RB-SiC for large, complex components. IntrinSiC® offers the globally-unique possibility of producing 3D-printed RB-SiC consistent with material produced using conventional manufacturing processes. It is also characterized by very high uniformity in all three spatial directions. Components up to a size of 1.8 m x 1.0 m x 0.7 m can be realized. In addition, IntrinSiC® offers the opportunity for maximum topology optimization. IntrinSiC® offers customers from a wide range of industries completely new possibilities, for example in industrial precision and metrology or space applications.

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