Advantages of Milling of Ceramics
Optimal for Parts Larger Than a Fist
Green machining is a
subtractive manufacturing method, meaning
costs don’t escalate dramatically as part size increases. Unlike
3D printing, which builds parts layer by layer, consuming extensive machine time, milling efficiently removes excess material from pressed ceramic blanks, keeping production
cost-effective for larger components.
Better Suited for Medium Production Runs (20+ Parts)
Initial setup, including CAD/CAM programming, typically incurs a
one-time cost of around
$200–$700 per part. However, the milling process itself is highly efficient, leveraging rapid axis movements and a high-speed spindle (42,000 RPM). With every additional part produced, the per-unit cost drops significantly compared to additive methods, making milling
economically attractive for series production.
Ideal for Wall Thicknesses Above 5 mm
Our pressed ceramic powders usually contain less than 4% organic binder, often even binder-free. This low binder content significantly streamlines the debinding process compared to 3D printing or injection molding, where binders constitute nearly 20% of the mass.
Thick-walled parts (>5 mm) are thus easily achievable without the risk of structural damage caused by internal gas pressure buildup during binder burnout.
Superior Mechanical Strength Compared to 3D-Printed Parts
The mechanical strength of ceramics greatly depends on microstructural homogeneity. Our
cold isostatic pressing at pressures up to
300 MPa (45,000 PSI) ensures exceptionally uniform compaction, virtually eliminating voids or inconsistencies and delivering the highest possible mechanical integrity in finished components.
Extensive Material Freedom
We can process virtually
any available ceramic powder. With trusted suppliers like
Alteo,
Almatis,
Nabaltec, or
Tosoh, our standard materials—
Al₂O₃,
ZrO₂, and
ZTA—are consistently in stock, either as raw powders or pressed preforms. Additionally, we custom-formulate ready-to-press blends for exotic ceramics such as Y₂O₃, AlN, SiC, and Si₃N₄, ensuring broad flexibility tailored precisely to your requirements.
Our standard U.S. lead time is
typically 5 weeks for
first-time orders. For subsequent repeat orders, we offer an
expedited production option with a rapid
2-week turnaround, allowing streamlined and predictable supply chain management.
Adequate Precision for Most Applications
Green machining precision is approximately ±10 µm, although a typical 20% shrinkage during sintering introduces slight distortion. Nevertheless, final dimensional tolerances remain within
±1% (minimum ±0.1 mm), sufficient for most industrial applications. If your application demands exceptionally tight tolerances, we offer precision hard grinding, achieving tolerances down to
±5 µm for critical features.
Cost-Efficient Machining of M6 and Larger Threads
While ceramic threads aren’t ideal for high-load fastening, certain applications necessitate their use. Fortunately, our milling allows for cost-effective integration of threads sized M6 and above without requiring additional grinding steps. Smaller or highly loaded threads should ideally be
ground post-sintering. For optimal performance and longevity, contact us for recommendations on alternative design approaches.
