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Our vertical integration is proven and extremely high.
This begins with the selection of the raw material in the form of granulate, continues with shaping, sintering and surface design using diamond tools and ends with assembly.
It takes place before sintering. We use the following processes for this:
This is one of our core competencies.
We produce ceramic components in two variants:
This has the advantage that extremely complex geometries can be realized at low tool costs.
This is mainly used for certain special materials.
Here, too, we use two methods:
For very large quantities with simple component geometries, the dry pressing process is the method of choice due to its speed and cost savings.
A pressure of 180 MPa is exerted isostatically on the elastic mold from all directions.
The process is particularly suitable for larger components of the highest quality and for the pre-series production of small quantities without having to invest in an expensive series tool. The process is also very fast.
Variable thermal processes are standard for us.
Our systems for this are energy-efficient, environmentally friendly and reliable.
Ceramic powder is just as unsuitable for molding as flour, for example. An organic binder is therefore added. This must be thermally removed from the ceramic blank before the actual sintering firing. This takes place in a controlled debinding furnace, whereby the organic components are completely thermally decomposed. Catalytic post-treatment ensures that the exhaust air is released into the atmosphere free of pollutants.
The still porous component is fired to produce a non-porous and dense component with the final material properties. A variety of ovens and variable processes guarantee an optimum result.
After sintering, there is still some post-processing to do. Any residues from test material for crack testing, cooling lubricants, abrasion from measuring devices or even just fingerprints affect the subsequent performance. Depending on customer requirements, conventional cleaning may not be sufficient. Some customers from the medical technology and high-performance electronics sectors receive an absolutely clean product, which is achieved through careful cleaning firing.
Green processing refers to the cutting of ceramic blanks in the unfired (green) state. The material is only leather-hard and can therefore be processed quickly by our CNC machines. As a result, geometries are possible that cannot be realized with normal pressing technology. Especially in combination with the CIP process, prototypes and pre-series can be produced quickly in small quantities.
A targeted firing for textile components. Thermal processes are used to give the surface of thread guides a special microstructure in order to create a so-called low friction surface with a very low-friction orange peel profile.
Other thermal processes such as glaze firing and metallization firing are also possible on request.
After sinter firing, the ceramic can only be processed with even harder diamond tools.
Ceramany has a very large precision grinding shop with a wide variety of processes.
We offer you:
Surface grinding, double surface grinding, polishing lapping,
multi-axis CNC coordinate grinding, centerless grinding,
superfinishing, honing,
various other polishing processes
We also offer you fully assembled components with ceramic inside.
Complete solutions from a single source reduce the complexity of the supply chain for you.
Regular employee training ensures our high quality standards. We document every production step
with the help of high-quality measuring instruments and test equipment.