Additive Manufactured Ceramic Components: Application Examples

From Two Parts to One Fully Integrated Component
This gas injector demonstrates the functional integration made possible by ceramic AM. Previously produced as a two-part assembly, it is now manufactured as a single, fully integrated component. Made from high-purity alumina (99.8%) using LCM, it includes three 6 mm channels, a flow-optimised internal honeycomb structure and 62 openings with 0.2 mm wall thickness — ideal for etching processes in semiconductor manufacturing.

Parameter

• Application: Gas injector for etching processes in the semiconductor industry
• Material: Alumina 99.8%
• Weight: 20 g
• Dimensions: Ø 20 mm (flange), Ø 9 mm (outlet), height 42 mm
• Technology: LCM
• Features: Three 6 mm channels; 62 openings; 0.2 mm wall thickness; honeycomb flow structure
• Advantages: High functional integration; chemical and thermal resistance; optimised flow; simplified assembly and maintenance; particle‑free operation

Periodic Open-Cell Structure for Efficient Reactions
This catalytic converter demonstrates how ceramic additive manufacturing unlocks new design possibilities for thermal and chemical processing. The periodic open-cell structure provides significantly increased surface area and optimised flow characteristics. The part withstands mechanical loads at high temperatures while enabling faster reactions, higher efficiency and longer component lifetimes, delivering both performance and cost advantages.

Parameter

• Application: Reactor catalyst for accelerating reactions of gases or liquids
• Material: Alumina 99.8%
• Weight: 313 g
• Dimensions: Ø 80 mm, height 100 mm
• Technology: LFD
• Features: Diamond‑inspired POCS structure with 2.5 mm struts
• Advantages: Highly porous flow‑through structure; large active surface area; optimal mixing and reaction efficiency

Precision and Efficiency in Series Manufacturing
This use case highlights the scalability of ceramic AM: a single build platform holds 444 identical needles. Used in Tailored Fiber Placement for processing abrasive fibres, the ceramic material ensures high wear resistance and prevents deflection thanks to its low density and high rigidity. The result is consistent precision across high-volume series production.

Parameter

• Application: Needle for textile processing (Tailored Fiber Placement)
• Material: Alumina 99.8%
• Weight: 0.5 g per needle
• Dimensions: Length 22.3 mm; thickness 1 mm; eye width 2 mm; clamping width 3 mm; eye diameter 1–1.5 mm
• Technology: LCM
• Features: Tolerance ±0.05 mm (0.002″)
• Advantages: 444 parts per print job; high wear resistance; low weight; no needle deflection

Precision Meets Thermal Stability
This component is used as a hold-down socket for automated laser welding processes in battery manufacturing. Because conductive materials are unsuitable in this environment, technical ceramics provide ideal electrical insulation combined with high thermal stability. Additive manufacturing enables geometries tailored to each weld seam, and internal channels support extraction of smoke, aerosols and debris directly at the weld point for a stable and clean process.

Parameter

• Application: Hold‑down socket for automated laser welding
• Material: Alumina 99.8%
• Weight: 23 g
• Dimensions: 12 × 20 × 20 mm (H × L × W)
• Technology: SLA
• Features: Integrated extraction channel, thread, and clamping features
• Advantages: Easy to clean; long service life; wear‑resistant; thermally stable

Efficient Heat Transfer Under Extreme Conditions
This compact ceramic heat exchanger (70 mm high, 50 mm diameter) is engineered for ultra-high operating temperatures up to 1400 °C. Its highly complex internal channel system (2 mm diameter) enables efficient fluid flow and optimised heat exchange in a minimal footprint. The component is impermeable to liquids and gases and offers superior thermal conductivity and specific electrical resistance, making it suitable for demanding cooling or heating tasks.

Parameter

• Application: Chemical processing; twisted channels for thermal exchange
• Material: Alumina 99.8%
• Weight: 2–14 g
• Dimensions: Height 20 mm; diameter 10 mm (example variant)
• Technology: LCM
• Features: Complex internal channels; service temperatures up to 1400 °C
• Advantages: Functionalised design; thermal conductivity 25 W/mK; specific electric resistance 10¹⁴ Ω·cm

High-Strength Medical Instrument with Integrated Functionality
This ceramic gripper is designed for surgical applications where precision, cleanliness and mechanical load capacity are essential. Two curved groove areas enable controlled gripping functions, while an internal channel allows for fluid application (air or water) or electrical wiring. With a density greater than 6.1 g/cm³ and closed porosity, the zirconia-based material offers significantly higher bending strength and fracture toughness compared to alumina.

Parameter

• Application: Medical instrument for surgical procedures
• Material: Zirconia (ZrO₂, 3 mol.% yttria stabilised)
• Weight: 0.57 g
• Dimensions: 19.5 × 4 × 2.5 mm (L × W × H)
• Technology: SLA & LCM
• Features: Internal channel; two curved groove areas; easy installation
• Advantages: Density >6.1 g/cm³; no open porosity; high strength and fracture toughness

From Two Parts to One Fully Integrated Component
This gas injector demonstrates the functional integration made possible by ceramic AM. Previously produced as a two-part assembly, it is now manufactured as a single, fully integrated component. Made from high-purity alumina (99.8%) using LCM, it includes three 6 mm channels, a flow-optimised internal honeycomb structure and 62 openings with 0.2 mm wall thickness — ideal for etching processes in semiconductor manufacturing.

Parameter

• Application: Gas injector for etching processes in the semiconductor industry
• Material: Alumina 99.8%
• Weight: 20 g
• Dimensions: Ø 20 mm (flange), Ø 9 mm (outlet), height 42 mm
• Technology: LCM
• Features: Three 6 mm channels; 62 openings; 0.2 mm wall thickness; honeycomb flow structure
• Advantages: High functional integration; chemical and thermal resistance; optimised flow; simplified assembly and maintenance; particle‑free operation

Precision Threads for Critical Applications
This ceramic fastener is designed as an insulating connector for demanding environments in the space industry. Creating internal and external threads in technical ceramics requires highly stable AM and sintering processes to ensure tight tolerances and reproducible performance. With extensive experience in ceramic AM, we manufacture complex threaded components (including UNEF and British Standard Whitworth threads) not only as prototypes but consistently in series production.

Parameter

• Application: Insulating ceramic connector for space applications
• Material: Zirconia
• Weight: 4,8
• Dimensions: 15 mm (length), 15 mm (wrench size), 17 mm (height). The outer thread is G 1/8 and has an outside diameter of 9.5 mm. The inner thread is UNEF 1/4 and has a bore diameter of 5.7 mm.
• Technology: LCM
• Features: Internal and external threads (UNEF, British Standard Whitworth)
• Advantages: Tight tolerances; reproducible series production; reliable performance in extreme environments