Integrated Threads via Ceramic 3D Printing: Insulating Connecting Piece for Aerospace Applications

In demanding operating environments such as aerospace engineering, where materials must withstand severe thermal and mechanical stresses, additively manufactured components made from technical ceramics are becoming increasingly vital. A current application demonstrates how high-performance ceramic serves as a precise mechanical interface and protective barrier for metallic systems: a pure ceramic thread adapter made of zirconia that integrates functional internal and external threads to directly accommodate customer screws while ensuring reliable dielectrical and thermal insulation.

Our latest application video demonstrates the mechanical assembly of the ceramic component with the metallic connecting elements in practical use:

Watch the Application Video on YouTube

Technical Specifications and Geometric Precision

Integrating thread profiles into monolithic ceramic components places exceptionally high demands on dimensional accuracy due to material-specific shrinkage during the sintering process. Sinto Advanced Ceramics' (formerly Bosch Advanced Ceramics) high-precision additive manufacturing process reliably maintains tight tolerances and strict contour accuracy. This ensures that the customer's standardized metal screws can be threaded directly into the printed tracks without clearance or binding.

The technical specifications of the connecting component at a glance:

• Material: Zirconia – selected for aerospace applications due to its high flexural strength, fracture toughness, excellent vacuum compatibility (zero outgassing), and reliable electrical and thermal insulation.
• Dimensions: Length: 15 mm | Wrench Size (HEX): 15 mm | Height: 17 mm.
• External Thread: G 1/8" (standardized pipe thread) with an outside diameter of 9.5 mm.
• Internal Thread: UNEF 1/4" (extra-fine thread) with a core hole diameter of 5.7 mm.
• Component Weight: 4.8 g (lightweight design matching strict aerospace weight specifications).
• Key Feature: Simultaneous additive integration of internal and external threads according to UNEF and British Standard Whitworth (BSW) standards.

Toolless Manufacturing of Complex Functional and Insulating Components

The component design demonstrates the capability of ceramic 3D printing to replicate standardized thread profiles directly layer by layer. This completely eliminates the need for expensive and time-consuming subtractive post-processing of the sintered part using grinding or diamond tools. The screw channels and thread pitches are formed directly inside the printer.

As a specialized contract manufacturer, Sinto Advanced Ceramics produces these complex connecting pieces based on customer CAD data in a standardized series production environment. The high repeatability of the additive process ensures that every component delivers the exact fits required for reliable operation, protection against electrical arcing, and secure mechanical coupling with metal components in aerospace engineering.