Do you need a suitable shaping method for your product, or do you have a shaping method that you wish to optimize?

We have a wide range of equipment for carrying out various shaping processes. The ceramic shaping processes can be divided into the basic types of pressing, plastic shaping, and casting. Because the differences between the shaping methods are significant, it is important to select a method that satisfies the requirements and is compatible with the properties of the ceramic product. We draw on a wealth of experience to select the shaping method according to the desired end properties of your ceramic. We would also be happy to advise you on product development with the help of innovative shaping methods.

1. Pressing

For high parts volumes and simple geometries, Das Bild zeigt das Werkzeug und den Grünling einer uniaxialen Presse nach dem Pressvorgangaxial dry pressing is the most economically efficient method. Complex geometries (recesses) can only be realized in the pressing direction. If production requires chip-forming machining of the green bodies, cold isostatic pressing is recommended for preparing uniformly densified blanks. We provide consulting on optimization of your pressing process or design of special press dies for producing your parts.

 

2. Plastic Shaping

Plastic shaping methods are suitable for mass production Das Bild zeigt einen Messextruder ohne Mundstück aus der technischen Ausstattung des FGKof complexly shaped parts. We have extensive experience in the extrusion of ceramic feedstocks and can assist you in developing components made of silicate ceramics or advanced ceramics. We can also offer expertise in the area of thermoplastic shaping. For injection molding at low pressure (hot casting) or high pressure, we are your partners for all tasks from preparation and characterization of thermoplastic masses to shaping.

 

3. Casting

Casting processes are suitable for the productionDas Bild zeigt wie der Gießschuh der Foliengießanlage mit Schlicker befüllt wird of samples of complex geometry (hot or injection molding) or very thin, flat components (tape casting). Our capabilities range from conventional slip casting of silicate ceramic products to hot casting or tape casting of advanced ceramics. We develop the process for your product and support you from the slurry and/or mass development up to the optimized casting process.

Our Laboratory and Pilot Facilities

Here, you will find a selection of our laboratory and pilot equipment for shaping. If you are interested in using our technical facilities, we would be happy to advise you individually.

Hand Lever Press PW 20 (Fa. P.O. Weber)

max. pressing force:
200 kN
max. piston stroke:
50 mm
Piston diameter:
80 mm
Applied piston surface:
50,27 cm²
max. working height:
230 mm
Available tools for samples:
Ø = 13 mm
Ø = 20 mm
Ø = 40 mm
30 x 60 mm
50 x 100 mm

Uniaxial press (Fa. Roperts & Kloft)

Recordable measurements:
Press force in tons
max. pressing force:
80 t
max. pressing stroke:
250 mm
Stroke of the lifter:
120 mm
Clamping surface (max. mold size):
ca. 500 x 500 mm
max. sample height:
50 - 60 mm pressed
Available Tools:
10 x 10 mm
15 x 15 mm
d = 30 mm

Cold isostatic press (Fa. National Forge EPSI)

Application area:
Production of green bodies
max. pressing force:
3800 bar
Programming:
Pressure build-up corresponds to pump output (non-adjustable), pressure relief from max. pressure to 200 bar unregulated via throttle valve, 200 - 0 bar decompression via pneumatically controlled automatic valve, holding times programmable
max. mold size:
d = 140 mm; l = 450 mm

Tape casting plant

Application area:
Casting of thin ceramic foils
Loading condition of the material:
Slurry suitable for tape casting
Material requirements for filling:
min. 200 ml
max. tape thickness:
Film applicator adjustable: 0 - 8 mm
max. tape width:
Film applicator width: 6 cm
Film applicator width: 14 cm
max. tape length:
120 cm
Drying:
External drying after casting process

Ceramic Slip Casting

Application area:
Manufacture of thin-walled ceramic hollow and solid bodies
Loading condition of the material:
Slurry
Available molds:
various plaster molds

Torque rheometer PolyLab OS (Fa. Haake)

Application area:
Investigation of the mass preparation by means of kneader and extrusion properties by means of extruder, filling degree investigations
Loading condition of the material:
Granules, powders, plastic and thermoplastic compositions
Specifications Extruder (Metering Feeder OS)
Conveying capacity:
up to 7,5 kg/h with powder
up to 14 kg/h with granules
material-dependent
max. torque:
1,1 Nm
max. rotation speed:
140 1/min
Screw:
Stainless steel Ø 14 mm
Conveying tube:
Stainless steel Ø 20 mm
Specification kneader (Rheomix 600 OS)
Chamber volume (without rotors):
120 cm³
max. torque:
160 Nm
max. rotation speed:
250 1/min
Heatable:
up to 400 °C

Vacuum extruder VAR 50A/50 (Fa. ETC Händle)

Application area:
Deaeration and extrusion of solid and hollow strands
Recordable measured values:
Speed for press screw, power of drive motors, vacuum, extrusion pressure, extrusion temperature
Maximum pressing force:
50 bar
Material requirements for filling:
min. 2 kg
Available mouthpiece geometries:
Round Ø 33 mm,
Trapezoid 22 x 20 x 15 mm,
Flat strand 40 x 7,5 mm,
Perforated sheet 2 mm

Vacuum extruder VARQ 50A (Fa. ETC Händle)

Application area:
Deaeration and extrusion of solid and hollow strands
Recordable measured values:
Speed for feeding and pressing screw, vacuum, extrusion pressure, extrusion temperature
Maximum pressing pressure:
150 bar
Material requirements for filling:
min. 5 kg
Available mouthpiece geometries:
Round Ø 33 mm,
Trapezoid 22 x 20 x 15 mm,
Flat strand 40 x 7,5 mm,
Perforated sheet 2 mm

Hot casting machine, low pressure injection moulding, GC-MPIM-2-MAX (Fa. Goceram)

Injection pressure:
max. 8 bar
Temperature range:
50 °C up to 120 °C
Mixing tank capacity:
max. 5 l
max. mold size:
200 x 200 x 120 mm

Hot casting machine, low pressure injection moulding, MIGL 33 (Fa. Peltsmann)

Injection pressure:
max. 5 bar
Temperatur range:
40 °C up to 150 °C
Injection time:
0,1 up to 90 sec
Mixing tank capacity:
max. 4 l
Mixing unit:
Planetary mixer

Injection molding machine Allrounder 270 C (Fa. Arburg)

Clamping force:
300 kN
Maximum tool diameter:
400 mm
Granulate container:
50 l
Injection unit:
Ø 15 mm
Ø 25 mm
max. stroke volume:
17 cm³
49 cm³
max. injection pressure:
2500 bar
2100 bar
max. ram pressure:
500 bar
250 bar
Screw circumference
Speed:
21 m/min
36 m/min