Sustainable Net Shaping
Sustainable Net Shaping: Innovations, Processes, and Possibilities
As our ceramic formulations continue to evolve to meet the needs of our customers challenges, so do our forming methods. CoorsTek offers several Sustainable Net Shaping methods which produce less waste than other traditional ceramic forming methods. Depending on the material, form factor, and application, our applications engineers partner with our customers to select the best sustainable net shaping method for your product.
Sustainable Net Shaping Methods
Injection Molding
Injection molding provides numerous benefits over other forming methods, offering less waste, higher yields, and lower total cost of ownership for high-volume production. As molded, injection molding generates a smooth surface – eliminating grinding and possible associated damage. With no or minimal post-processing, there is less surface area for reaction.
Sizes of parts developed with injection molding are typically small to medium. However, CoorsTek is developing technology for larger parts. For geometrically enabled parts, injection molding can reduce or eliminate costly secondary unit operations and is targeted to 100% as-fired geometries. >> Learn More about Injection Molding
Ceramic 3D Printing
Ceramic 3D printing offers several advantages, including design flexibility, customization, reduced lead times, and reduced waste. 3D printing allows for the creation of complex shapes and intricate designs that are not possible using other ceramic forming methods, making this an ideal forming method for semiconductor, aerospace, medical, and electronic applications. As compared to other ceramic forming methods, 3D printing minimizes material waste, leading to long-term environmental benefits.
Extrusion
Ceramic extrusion is an ideal method for creating long, continuous shapes with complex cross sections. The process involves pushing a moldable ceramic mixture through a shaped die. As the mass is pushed through, it will take on the cross-sectional shape of the die, including the creation of internal channels.
Extrusion provides numerous advantages, including continuous production of long shapes with continuous dimensions, the ability to create complex cross-sections, and high throughput—resulting in less waste to minimize environmental impacts.
Crystallographic Bonding: Increased Range of Sizes & Shapes
CoorsTek has developed a reliable, proprietary bonding technology to reduce costs and enable bulk production. Unlike diffusion bonded materials, CoorsTek Crystallographic Bonding technology shows no visible bonding interface. The materials are without the known defects originating from diffusion bonding.Materials
Sustainable Net Shaping methods can be utilized for a wide range of materials, making these methods available to a wide range of applications. Compositions including Aluminas, Yttrias, Zirconia Toughened Aluminas, Polycrystalline Alumina, and Silicon Nitride are all suitable materials for Sustainable Net Shaping methods.
Essentially, any CoorsTek powder-based composition can be adaptable for injection molding or other Sustainable Net Shaping Methods.
With sustainable net shaping and a wide range of ceramic firing and finishing capabilities, our design engineers work closely with customers to identify the most effective solution for their unique challenges. We are continually expanding our ceramic formulations to eet the evoloving needs of our customers, with processes designed to scale efficiently from small prototype runs to high-volume production. Our capabilities target 100% as-fired geometries, reducing or eliminating the need for secondary machining.
Connect with CoorsTek design engineers today to explore sustainable net shaping solutions tailored to your application requirements.