Learn how ceramic additive manufacturing can be an alternative to conventional manufacturing methods
4 Day ONLINE COURSE
October 26-29 from 10:30 a.m. – Noon ET
Moderator: Shawn M. Allan, vice president, Lithoz America LLC
Ceramic additive manufacturing has the potential to radically change the market. The available manufacturing systems for ceramic have reached an advanced stage already and present a real alternative and a sensible addition to conventional manufacturing methods. This tendency of development has awakened great interest in industry and research, but also great uncertainty. It is therefore necessary to offer a deep insight into the subject to uncover the potential of the technology. The course provides its audience a varied program which contains a mixture of economic, application-specific and technology-based topics. The course includes the following topics:
- Session 1: General Overview and Market Considerations
- Session 2: AM Methods
- Session 3: AM Manufacturing
- Session 4: New Developments and Panel Discussion
The course is specifically suitable for people from the fields of company strategy & development, research and development, universities, construction, design, production, supply chain management, product development, and innovation development.
Attendees will get an introduction into the topic of additive manufacturing (AM) ceramics and learn more about the economical and technical aspects of this new technology. Furthermore, attendees get an overview of state-of-the-art production methods as well as a deeper insight into opportunities and limitations of the new technology. Attendees will also gain a basic understanding of how to implement AM systems into their production chain, and learn what kind of applications are recommended for additive manufacturing. By the end of the course, attendees will understand the pros and cons of different technologies and will be able to use their gained knowledge in the strategic planning.
Bio: Shulman joined Alfred University in 2017 as professor of ceramic engineering. Her research interests include extreme environment materials and electro-ceramics. She has 30+ years experience in R&D, working on industrial challenges and innovations. Shulman founded Ceralink Inc. in 2000, and created a hands-on dynamic team to develop and test new products and processes. She previously worked for Kennametal Inc, Materials and Electrochemical Research, and Crown Research Institute in New Zealand. Shulman earned her Ph.D. in the ceramics laboratory at the Swiss Federal Institute of Technology, an M.S. in materials science at University of Pittsburgh, and a B.S. in ceramic engineering at Alfred University.
Overview of Ceramic Additive Manufacturing
There are many platform choices for Additive Manufacturing (AM) of ceramics, and it is important to understand how these different methods may impact the final product. AM is typically thought of as a forming process in ceramics. Ceramic properties can be extremely sensitive to forming method, and are affected by variables such as particle size, morphology and packing, organic additive type and quantity, as well as stresses applied during forming. This talk will identify the platforms and methods available for AM of ceramics and explain how they work. The advantages and limitations will be discussed, to enable down selection of the appropriate platform for specific applications. Finally, some thoughts will be shared on areas for advancement and future direction of Ceramic AM.
Bio: Johannes received his master’s degree in industrial engineering at Vienna University of Technology in 2005, and finished his Ph.D there in 2008. He has been teaching since 2009 at different universities, and is the co-inventor of three patents. Homa is the co-founder and CEO of Lithoz GmbH. Lithoz GmbH is based in Vienna, Austria and is the world leader in additive manufacturing of high-perfomance ceramic components.
Ceramic Additive Manufacturing Marketing Considerations
Over the past few years, additive manufacturing (AM) has grown to become a highly advanced and capable manufacturing technique. However, its primary use is no longer for prototyping, but instead for serial production. However, new developments such multi-material printing with AM have also created regular hype in different fields and many people expect this technology to lead to the next industrial revolution.
By showcasing different examples of AM complementing existing ceramic production methods, the real potential and strength of this method is clear to see. It is shown that AM possesses undisputable potential for customization, small-scale series and highly complex designs, making it a valuable complement - but not a substitute - for existing manufacturing techniques in the ceramic industry.
Bio: Blacker is product development manager and principal investigator at ExOne. He has a bachelor's degree in mechanical engineering from the University of Cincinnati and has served as senior program manager and technical principal investigator for numerous advanced materials research and development programs for both government and commercial customers, including numerous SBIR programs. Blacker is leading ExOne’s new material development efforts in the areas of ceramics, carbon, and refractory metals. He is currently principal investigator on a three-year, $1.5M contract with the U.S. Missile Defense Agency entitled “Three-Dimensional Printing of Silicon Carbide for Optical Structures."
Binder Jetting Additive Manufacturing of Ceramic Materials.
Blacker will review the current state of the art in terms of binder jetting machine capabilities as it relates to ceramic powder printing, as well as discuss applications of binder jetting AM for ceramic materials.
Bio: Allan is vice president of Lithoz America LLC. He earned his bachelor's degree in materials science and engineering from Alfred University and his master's degree from Georgia Tech. He has worked in materials for nearly 20 years, with focus on forming and sintering processes for a variety of ceramic materials. Allan is co-inventor of two patents and co-authored over 30 publications and conference presentations, resulting from a wide array of collaborative commercially-applied materials processing R&D.
Lithography-based Ceramic Manufacturing
Bio: Thomas Henriksen is president of Ceramco, an OEM manufacturer of custom technical ceramics of complex geometries for customer-specific applications, serving the aviation & aerospace, scientific instrumentation, energy R&D and production, and consumer products & wearable technology markets.
Applications and experiences as a manufacturer - LCM
As the first OEM in the USA to offer lithography-based ceramic manufacturing (LCM) to its customers, Ceramco has experience making parts for many applications, including space and aerospace, medical, and semiconductor. High-quality, high-performance ceramic materials such as aluminum oxide, zirconium dioxide, and silicon nitride are made using Lithoz CeraFab machines. Process capabilities are explored, limitations in size ranges are considered and also exceeded, and special techniques are developed from years of experience, giving industrial/commercial, university level, and individuals access to technical ceramics like never before. These manufacturing challenges are shared, to help the additive community understand what is so unique about producing parts in ceramic materials.
Bio: Hoel is senior materials scientist for the General Electric Research Center, where she evaluates additive manufacturing as process to fabricate complex ceramic components. She identifies where additive ceramics can play a disruptive role in next generation technology and fabricating prototypes. Hoel previously worked on thermal barrier coatings to increase their capability in extreme environmental conditions. She also developed processes that enable forming complex ceramic components and helped scale and transition the technology to a production environment. Hoel analyzed binder decomposition reactions and how they influenced the physical properties of the ceramic for a stress model of the process. She also developed novel ceramic slurry compositions and methods for assessing variation across components. Hoel earned a Ph.D. in chemistry from Northwestern University and a B.A. in chemistry from Washington University in St. Louis.
Practical Considerations for Ceramic Additive Manufacturing from Conception to Production
This presentation is for anyone who wants to bring the benefits of additively manufactured ceramics to their products and customers. We will review how to down-select the most appropriate modality, how to determine if it is a viable business case, and what challenges need to be addressed for scaling up to production levels.
Bio: Dr. Schwentenwein is the head of Materials Development at Lithoz GmbH
New Developments in Ceramic Additive Manufacturing
3D printing or the additive manufacturing (AM) of ceramics using lithography-based techniques has been garnering more and more attention in recent times. Using this method, it is possible to combine the high precision and flexibility of lithographic AM processes with the exceptional material properties of ceramics, meaning that completely new application areas are opened up.
This presentation will discuss the different concepts on how to use lithographic shaping techniques to produce ceramic and even metal components, mainly through using photocurable suspensions with a high solids loading of ceramic or metallic particles and a subsequent standard sintering process, or via a procedure involving so-called preceramic polymers that can be converted into ceramic components by a pyrolytic process.
This presentation will discuss new material developments in the field of lithographic AM that include piezoceramics, aluminium nitride, and reaction-bonded silicon carbide among other materials. It will also highlight novel technological developments such as lithographic multi-material printing that allows different ceramic materials to be combined in a single compound.
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