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Custom Ceramic Manufacturing Services

Ceramics resist heat, wear, chemicals, and corrosion, which is why they are considered a suitable replacement for metal parts in many applications. In reality, these materials are used less in commercial and industrial applications because they are not easy to work with and more challenging to manufacture. However, 3D printing has made it easier to work with these materials than ever before. Marvel Medtech Advanced Manufacturing specializes in 3D printing  (additive manufacturing – AM) of advanced technical ceramics. We use the revolutionary patented NanoParticle Jetting™ (NPJ™) system from XJet Ltd. to create custom ceramic parts to meet each customer’s unique needs. As an experienced custom ceramic parts manufacturer, we have developed unique expertise in using the XJet NPJ™ AM system and delivered hundreds of custom ceramic parts with complex part geometries and demanding design details. Our in-depth understanding of the properties of advanced technical ceramics combined with XJet NPJ™ has helped clients exploit the potential of advanced technical ceramics to the fullest.
 
Additive Manufacturing of Zirconia Advanced Ceramics

An Overview of Custom Ceramic Manufacturing Services at Marvel Medtech Advanced Manufacturing

XJet’s NPJ TM is a proprietary technology that builds custom ceramic parts layer-by-layer in ultra-thin (10 micrometer) slices for high dimensional precision and small feature size capability. Solid nanoparticles of ceramic in a liquid suspension are loaded safely into the printer. This helps operators avoid using any hazardous powders for loading the material into the printer, and also minimizes raw material waste. Next, the printer heads featuring thousands of inkjet nozzles jet millions of fine drops of ceramic and support ink onto the build tray in ultrafine layers. The support ink helps keep the ceramic particles intact. Also, liquid jetting in ultrathin layers helps produce high-quality parts of unlimited geometrical complexity. Once the part printing completes, the water-soluble support material is gently removed in a water bath without affecting the part. This helps avoid costly post-processing. After cleaning and drying, the green ceramic parts  are  sintered in a similar way as traditional ceramic parts.

Materials We Work With

As a custom ceramic parts manufacturer, we regularly work with the below advanced technical ceramics:

  • High Purity Alumina (Al2O3): We feature alumina with purity of 99.9+%. Ceramic alumina  is known for its high durability, exceptional hardness, and high temperature resistance. It is frequently used as an insulator in electrical applications and where chemical and corrosion resistance are important design considerations.
  • Yittria (Y2O3) – Partially Stabilized Zirconia (ZrO2): Zirconia ceramic partially stabilized with yttria is one of the strongest ceramic materials with excellent mechanical properties and superb toughness.  It is biocompatible and is commonly used for dental implants, surgical tools and other medical device applications.

 

Material Properties

Material Zirconia (ZrO2) Alumina (Al2O3)
Density (g/cc) 6.02 3.92
Hardness (GPa) 12.7 14.5
Flex Strength (MPa) 1240 430
Fracture Toughness (MPa/m) 13 4-5
Thermal Conductivity (W/mk) 2.2 37

Benefits of Custom Ceramic Manufacturing with XJet NPJ™ 3D Printing

Custom ceramic manufacturing using XJet NPJ™ 3D printing is rapidly gaining popularity because it enables a whole new level of design freedom to create complex part designs that cannot be manufactured in any other way.  Advantages of custom ceramic additive manufacturing with XJet NPJ™ include:

  • High Level of Customization: As said before, Marvel Medtech Advanced Manufacturing has developed unique expertise in the application of the XJet NPJ™ technology. We have been able to push the limits of the NPJ™ capabilities to meet our customer’s unique customization needs and enable new technical ceramics applications.
  • Great Design Freedom: XJet NPJ™ technology has enabled a whole new paradigm of design freedom and flexibility. There is virtually no limitation on part geometries and intricate features that one can include in custom AM ceramic parts.
  • Quick Turnaround Times: Unlike ”legacy” ceramics manufacturing technologies, additive manufacturing requires no additional tooling. This helps assure quick turnaround times and has helped our clients accelerate their time-to-market capabilities.
  • Profitability: Although additive manufacturing is projected as an expensive technology by many, accuracy, turnaround times, and design freedom are a few factors that make the technology profitable for the production of custom ceramic parts.
  • Sustainable Manufacturing: Custom ceramic manufacturing using the XJet NPJ™ 3D printing process can be hailed as sustainable manufacturing because it reduces raw material waste to virtually nothing. High-precision jetting of ceramic nanoparticles suspended in ink enables use of only the amount of raw materials required to build the part model.

Custom Ceramic Parts

As an innovative and experienced technical ceramic parts manufacturer, we have had the privilege of serving clients across medical, aerospace/defense, energy, automotive/transportation, and other industries with custom ceramic additive manufacturing parts. The following are a few custom ceramics parts that we’ve manufactured:

  • Surgical tools
  • Insulation components
  • Heating components and heat recovery components
  • Heat exchangers
  • Housings
  • Clamps and fixing supports

Feel free to contact our team today for any questions on our custom ceramic manufacturing services. You can call us at 1-877-345-6261 or 1-608-688-0868. You can Request a Quote for Your Project to receive a secure file upload link.