Broadening the use of Technical Ceramics with 3D printing

Broadening the use of Technical
Ceramics with 3D printing
Hall 16 Booth A91
Richard GAIGNON
Ceramic by 3D
To print or not to print?
This was also our question !
when we start the adventure 10 years ago…
2
3DCeram: a real study case
C.Chaput printed his first ceramic par in 1998 with
SLA,
2001: Cerampilot (former name of 3DCeram)
created in Limoges, France,
2005: first contract
implant
2009 to print biomedical skull
2015
Turn over
Turn over
Cerampilot
3DCeram
Pressing
3DPrinting
Casting
3D printing is the reason
of this development
Quality, same properties as parts made
by pressing or injection,
Flexibility and speed, production or
development within a very short time:
of prototypes,
of unique parts,
of series-produced components.
Possibility to produce just about any
shape, even complex,
3DCeram: keep moving !
2014: Decision to launch the CERAMAKER
production line to the ceramic world
Our Know how
Ceramic consumables:
Al2O3, ATZ, ZrO2, HAP, TCP and customized
solution paste,
a 3D SLA printer dedicated to ceramics (large
printed area of 300*300)
On demand 3D printing manufacturing of parts
A break through technology
Stereolithography applied to advanced ceramic
SLA PROCESS
1.
2.
3.
4.
5.
Creation of the CAD
Export to STL file and
slicing
Printing layer by
layer.
Debinding and
sintering (shrinkage)
Finishes
Pre printing process
Export in STL format
Design of the support
Pre printing process
Import of all STL files
Creation of the working tank with proper
anamorphosis
Layering n
Lasering n
Z axis going down n+1
Layering n+1
Lasering n+1
Printing surface optimisation
Post printing
Debinding Sintering
About 20% shrinkage
Green part
Sintered part
Post printing
Step 7 : Post-treatments
Post Treatments, in function of
the needs :
• Maschining
• Polishing
• Sterilization
• …
Roughness :
•
Ra before polishing step ~1-2 µm
•
Ra after polishing step ~0,02-0,04 µm
The process is simple
If you
control each step
Fired
density
Specific
Surface
Green
density
Application
(Use)
Granulo
métry
debinding
Mineral
composition
Ceramic
choice
Firing,
UV source
Load
Thickness
of layers
Layering
technology
3DPrinting
technology
Paste
formulation
Rhéology
Réactivity
Fired
density
Specific
surface
Green
density
Application
(use)
Granul
ométry
debinding
Firing,
Choix de la
source
d’insolation
Epaisseur
des
couches
Mise en couche
Need of global
approach for:
•the raw material,
•the paste,
•the machine
Minéral
content
Ceramic
choice
Loading
content
3Dprinting
technology
Paste
formulation
Rhéolo
gy
Réactivity
SLA experience at 3DCeram
Since 2005, the company has been using SLA printer
for the MANUFACTURING of prototypes, one-off parts
and small runs.
Some parts made by
Ceramaker
Porous and dense areas
combined on the same implant
CLINICAL CASE #1
Ref : Case #1
Age : 27 years
Sex : Male
Surgery date : 07/01/2005
Surgery duration : 180 min
Implant surface : 7 x 5 cm
Implant thickness : 5 mm
Fixation holes : 4
Topography : Orbitofrontal
M1
M12
Paving your way
to
Ceramic 3Dprinting
26
SLA: Communication or
Actual innovation
Traditionnal way to manufacture ceramic are synonym of long
delivery, expensive and « know how intensive ».
Traditionnal
technology
3D printing
Complex shape
++
++++++
Development time
Few months
Fews weeks
Tooling
10 to 150 K€
none
Minimum qty manufactered
> 5000 about
No minimum
threshold
 3D printing is one answer to the market
need
 Reduced time to market
 No minimum qty
 Lower technical barrier
27
Some Q/A about 3D printing
Is everything possible by 3Dprinting?
No!
3D printing should subsitute to the current technologies:
No! 3D printing should be used to assist existing technologies
3D printing is only for prototyping!
No! It is a mass customisation technology.
3D printing is less expensive than existing technologies:
Not always ! It depends on shape, delivery time, quantities…
28
How to boost ceramic 3D
printing?
Ceramic 3D printing is way behind plastic and metal 3D printing.
What is missing to developp ceramic 3D printing (Printing Equipment?
Feedstock? Norms? R&D? Technical center? Public Funds?..)
Ceramic industry is a conservative environment,
Think out of the box ! Forget to think with what you learned at school…
Few serious turn key offers (equipment / feedstock / training).
Some of equipment manufacturers knows NOTHING about Ceramic and
promises EVERYTHING.
Printing is not difficult but printing and firing (repeatability) a Good
ceramic is !
This is why Ceramic is so different. Ceramic knowledge is a must.
29
To print or not to print?
It is a TOP management decision. It impacts the whole organisation
It is a mindset evolution and technology revolution
3D printing is clearly an opportunity. Take it !
Potter
First
industrial
revolution
Ceramic
engineer
Ceramic
makers
Second
Third
industrial
revolution
industrial
revolution
30
Thank You ! We all makers.
Potter
First
industrial
revolution
Ceramic
engineer
Ceramic
makers
Second
Third
industrial
revolution
industrial
revolution
Richard Gaignon
+33 6 40 15 24 68
Richard.gaignon@3dceram.com
www.3DCeram.com
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