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CeraFab Serial Production System – S25, S65, S230

  • Serial production
  • Easy industrial scale-up
  • Consolidated reliability
  • llOT and Industry 4.0 ready

Industry-leading and trusted 3D printers, designed for scalability and ready for advanced developments and serial production.

The CeraFab System family is the ultimate choice for enabling the industrial serial production of high-performance ceramics using additive manufacturing. Each machine in the CeraFab System family, consisting of the S25, S65 and S230, offers a full 3D printing system for advanced developments. A total of four production units can be combined, making it easy to scale-up and enabling the rapid manufacture of exceptional ceramic components. From small-scale to large part production, these machines can accommodate all types of high-quality 3D printing projects thanks to their different build volumes and have the fastest building speed on the market. The current generation of projectors with WQXGA resolution, in combination with an objective lens specially developed for the process, ensures the absolute precision of printed components – even in the micrometer range.

Industrial Internet of Things and Industry 4.0 ready

A central element of the CeraFab System is the automatic creation of a database for storing and handling process data, which facilitates the seamless documentation of print jobs. An optional add-on allows for real-time monitoring and control of the process via live-video remote transmission.

 

AVAILABLE MATERIALS FOR THE LCM PROCESS

Lithoz offers its customers various materials for the additive manufacturing of high-performance and bio-resorbable ceramics. Each raw material has been developed to perfectly suit Lithoz’s technology and to facilitate the production of high-quality parts.

STANDARD MATERIALS

ALUMINUM OXIDE

LithaLox HP 500 and LithaLox 350 are a high-purity aluminum oxide (99.99 % and 99.8 % respectively). Alumina is one of the most important oxide ceramic materials and is characterized by high levels of hardness as well as good corrosion and temperature resistance. Components made from alumina are electrically insulating and puncture-proof and are therefore suitable for a wide range of applications, such as substrates in the electronics industry, thread guides in textile engineering, protection in thermal processes and many others.

ZIRCONIA

LithaCon 3Y 210 and LithaCon 3Y 230 are a 3 mol% yttria stabilized zirconia. Zirconia is used for applications with extreme demands on the material. High-end metal forming, valves, bearings and cutting tools are some of the applications which benefit from the mechanical properties of zirconia. The biocompatibility of zirconia facilitates its use in medical applications, such as dental applications and as part of permanent implants.

SILICON NITRIDE

LithaNit 770 is a Beta-SiAlON type ceramic. It exhibits superior material properties such as high strength, high toughness, thermal shock resistance and good chemical resistance to corrosion by many acids and alkalis.

LithaNit 770 has a wide range of applications including insulators, springs, impellers and more. Furthermore, it can be used for the medical engineering of permanent implants due to its osseointegrative potential and anti-infective properties.

MATERIALS FOR SPECIAL APPLICATIONS

TRICALCIUM PHOSPHATE AS BONE-REPLACEMENT MATERIAL

LithaBone TCP 300 is a beta-tricalcium phosphate (ß-TCP) based ceramic. Tricalcium phosphate (TCP) exhibits excellent biocompatibility, bioresorbability and osteoconductivity, and is therefore a well-established material for bone replacement in regenerative medicine. Due to its properties, it is possible to manufacture patient-specific resorbable implants with defined pore structures and geometries using this material. During the healing phase, these implants will be resorbed by the body and replaced by native bone tissue, meaning that a second surgery for the removal of the implant is not necessary.

HYDROXYAPATITE AS BONE-REPLACEMENT MATERIAL

LithaBone HA 400 is based upon hydroxyapatite, a naturally occurring mineral that forms the main component of bones. Due to its similarities to the inorganic components of bone, HA possesses excellent biocompatibility and osteoconductivity and has a number of potential applications as a bone substitute. In comparison to tricalcium phosphate, hydroxyapatite takes far more time to be absorbed into the body, therefore giving the body more time to heal. Using HA, we can manufacture patient-specific, bio-resorbable implants, which have defined pore structures and geometries. These implants will be reabsorbed by the body and will be replaced by native bone tissue, meaning that the implant does not need to be removed once the healing process is finished.

SILICA-BASED MATERIALS FOR CASTING CORES

LithaCore 450 is mainly based on silica with addition of alumina and zircon. It is used for the production of casting cores for investment casting. Typical applications include single crystal casting of turbine blades. LithaCore 450 is developed for the additive manufacturing of precise ceramic cores with fine details and high accuracy. Sintered ceramic cores made from LithaCore 450 have very low thermal dilatation up to 1500 °C, a high porosity, outstanding surface quality and a very good leachability.

TAKE ADVANTAGE OF OUR OPEN SYSTEM

With the LCM technology, Lithoz has created an open system through which many different ceramic materials can be handled. This provides the opportunity to process customer-specific powders without the need for any system modification, meaning that our LCM technology is suited for processing sinterable powders. In the past few years, we have successfully processed the following materials (amongst others) using the LCM-technology:

Alumina toughened zirconia (ATZ) Cordierite
Glass-ceramics Piezoceramics
Zirconia toughened alumina (ZTA) Magnesia
Transparent ceramics RF dielectric ceramics
Cermets Porcelain
Bioglass Titanium dioxide

DATABASE-DRIVEN SOFTWARE FOR YOUR DIGITAL PRODUCTION Database-Driven Software For Your Digital Production

Lithoz CeraFab Control is a powerful database-driven software platform to promote complete traceability, intelligent data analysis of production related data and greater efficiency in manufacturing. Job preparation becomes simpler and more intuitive with the integration of tried-and-tested process parameters for all ceramic materials. Large volumes of production data are centrally stored for an additive manufacturing process ready for Industry 4.0. Users will have the ability to make faster, better-informed decisions.

Thanks to new optional modules, application and new material development greatly benefit from being able to make real-time adjustments to advanced printing parameters and the building process. On top of this, customers can reliably implement quality assurance, while also ensuring that the 3D printing processes are optimized for maximum productivity.

How lithography-based ceramic AM is expanding the opportunities for technical ceramics

The impact of Additive Manufacturing is today being felt far beyond the metal and plastics industry. This is particularly true in the world of technical ceramics, where processes such as Lithography-based Ceramic Manufacturing are opening up new markets for new applications but also supporting technologies such as Ceramic Injection Molding through the delivery of functional prototypes. In the following report Lithoz GmbH, reviews the process, its parallels with CIM, and the opportunities that it presents to the ceramics industry.