Focus published in November 2024, created in collaboration with 3DCeram. The manufacturer’s statements below refer to that interview.
“Better, faster, cheaper.” These objectives accompany additive manufacturing’s transition to industrial production. In this interview, 3DCeram discusses its approach to ceramic 3D printing by stereolithography (SLA), from part preparation to automation.
The company develops printers and services for this production chain. Our coverage of 3DCeram has included applications in healthcare, aerospace and energy. This conversation focuses on process selection and the conditions for series production.
“Manufacturers who seek production solutions through 3D printing usually do so under the impetus of a specific project,” the 3DCeram team explains from the outset. “This means that manufacturers who consider additive manufacturing to be a full-fledged production tool are growing in number. But some got a little confused by the diversity of technological offerings. Let’s admit that there is a proliferation of technologies (extrusion, FFF, DLP, Binder Jetting, Stereolithography…) emanating from the academic sector, but this often confuses manufacturers. It makes their journey longer.”
According to the 3DCeram team, SLA has a reputation for being a “slow process”. In contrast, the technology “offers the possibility of very large printing areas thanks to top-down printing [and] is most easily automated.”
Moving toward industrial production
In the top-down configuration described by 3DCeram, exposure takes place at the top of the vat and the platform descends between layers, building the part from the bottom up. The manufacturer highlights fewer supports, or support-free printing for some geometries. Support requirements still depend on the part and process.
Manufacturing continues after printing: post-processing includes cleaning, debinding and sintering. Line throughput therefore needs to account for these operations and the checks required by the application.
Automation, artificial intelligence assistance and large-part capacity are among the priorities highlighted by 3DCeram. Their effect on costs and lead times depends on the intended production.
“SLA is a technology that offers significantly large production surfaces, with the possibility to add lasers and to enhance the printing speed,” 3DCeram said. Besides this key asset for manufacturers looking for mass production, the company’s systems are large enough to print either small or big parts.
Moreover, process automation is essential if we want to reach manufacturers, and here 3DCeram already offers partial automation of the process. “Our 3D Printers have a formulation feed system with a pressurized pot. At the output of the C1000 FLEXMATIC printer, there is a recycling station that allows the recovery of unpolymerized formulation, which then goes back into the production cycle. The printing surfaces of 3DCeram’s CERAMAKER printers offer the possibility of printing very large parts. For instance, with the C3601 ULTIMATE whose platform is 600*600*300 mm, there is a considerable space to print large [parts] and in ONE PIECE!” the company adds.
The 600 × 600 × 300 mm dimensions listed for the C3601 ULTIMATE describe a three-dimensional build envelope. They are not guaranteed final part dimensions after thermal processing.
CERIA: assistance with preparation and control
In June 2024, 3DCeram introduced CERIA Set as an assistant for checking files, arranging the vat and proposing parameters for CERAMAKER printers. During the interview, the team described its objectives and a planned CERIA Live module for the end of 2024:
“First, the CERIA Set analyzes the part and the VAT to propose adjustments and generate optimized parameters. This means it will cross-reference incredible amounts of data to make a complete analysis and anticipate all areas of improvement. Once all adjustments are made, CERIA generates ready-to-use printing parameters for CERAMAKER printers. The operator then only has to start the printing.
This new tool is a major asset for a manufacturer as it responds to the need to secure their production process. Indeed, all the knowledge is no longer held by a collaborator who could decide to leave the company. The risk of disruption in the production chain is then eliminated.
Another major contribution of CERIA is the time saved in terms of iterations. We know that, as with any industrial process, there are rejects or failures. The contribution of CERIA here is considerable, as it produces gains in time, raw materials, and machines.
3DCeram will be launching at the end of 2024, a complementary module to its artificial intelligence, CERIA Live. This module is about real-time control during printing. CERIA analyzes the previous 3 layers to anticipate all events that could occur in the next 5 layers and intervene to make necessary adjustments. The idea here is to control all parameters in real-time to optimize printing time.”
These savings and the claimed elimination of risk are the manufacturer’s statements. The interview provides no independent comparative test protocol to quantify them. Software assistance does not remove the need for production qualification or operator expertise. The CERIA Live announcement above records the timetable envisaged in 2024; it does not establish its actual release date.
Organisational barriers and applications
Beyond machine capability, the company identifies gaps in process knowledge, uncertainty about which parts to manufacture and the transition from small batches to larger volumes. 3DCeram draws on its progression from part manufacturing to printer manufacturing when supporting that transition.
The team sets out its view of automation and industrial requirements:
“All technical ceramics manufacturers will benefit from optimizing AM processes assisted by artificial intelligence and automation. Manufacturers can finally design parts based on the properties they are seeking, rather than being constrained by the traditional processes available in their workshops. The locks are falling and manufacturers are increasingly attentive. At the forefront are all the productions associated with sovereignty and confidentiality issues. We can see that these issues are more and more numerous and more present than ever,” 3DCeram outlines.
The manufacturer describes applications in semiconductors, as well as defence and aerospace. Each case needs to be assessed against its part, material and qualification requirements.
Editor’s notes
At publication, 3DCeram was announcing a CERIA presentation at Formnext, from November 19 to 22, 2024, in Hall 11.1, Stand D21. This information is retained as historical context.
Quotations have been edited for clarity. Specifications and performance claims remain attributed to 3DCeram.
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