Nanopoudres pour l'industrie de la céramique

Use case “Zetamix 3D printing: an effective and low-cost internal solution.”

28/05/2019

New possibilities with Zetamix filament.
In industries such as medical, automotive, aerospace or semiconductor, the use of parts with complex geometries and in small quantities is common. One must nevertheless note that these kind of parts and geometries are very often impracticable with traditional ways.

His role is to regularly monitor the proper functioning of Nanoe’s equipment and infrastructure. As part of preventive maintenance, Bastien intended to change the rotary nozzle head of Nanoe spray dryer. However, the supplier of spare parts could no longer manufacture this part. On the other side switching a supplier involves supplementary steps and long delays, he says.

That’s when Zetamix 3D printing comes in!
Nanoe company launches the first ever ceramic and metal desktop 3D printing system. For this printer, Zetamix filaments are suitable for any FDM technologies. It is now possible to print parts which contain more than 80%w of ceramic or metal. They are constituted of a polymer matrix and a ceramic or metal powder. Depending on the application or need, it is important to choose suitable materials to ensure wear resistance, corrosion resistance and the lifetime of manufactured advanced components. So far, Nanoe has developed filaments loaded with alumina, white zirconia, black zirconia, ZTA, stainless steel, silicon carbide, silicon nitride, and tungsten carbide.

The printed parts are chemically debinded in acetone and then sintered in a furnace.

This technology offers manufacturers an efficient solution:

Regarding the specificities of the ceramic part:

Here, it is a zirconia part in conical shape. It is drilled from side to side, to be taken into sandwiched between the two-metal side that we see on the complete nozzle.

The plots are not very difficult to make with FDM 3D printer. Nevertheless, the twelve parts must be exactly the same weight in order to avoid an unbalanced nozzle. Thanks to our Zetamix solutions, the twelve plots can be printed at once without a great difference in mass between all parts.

Thus, Zetamix filaments could be used for tooling, prototyping, and used for making small batches of products.

That being said, it is important to bear in mind that depending on the geometry of the finished part and the material several forming steps can be necessary. For this reason, Zetamix 3D printing is a method of manufacturing that has many advantages including: time and cost. Between the time you contact a supplier and when you are delivered, it can take several months because of: the preparation and validation of the estimate, manufacturing time and delivery times. In terms of cost, Nanoe has estimated that the manufacture of this part would have cost 3960€ against 100€ with internal solution.

To remedy this situation and to ensure quality performance, Nanoe works with customers to reduce their product development lead times by facilitating prototyping with end-use materials.

Key success factors for this process:
• 15 minutes of 3D printing
• 1 week to sinter the part
• Low cost to make the ceramic part

Making these parts with a subcontractor would involve more time, cost and processes. By opting for Zetamix 3D printing, one can create and produce custom replacement parts on demand with significantly lower costs.


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