CERACAT 3D Printed

Ceramic Foundry consumables

The CERACAT 3D System is a groundbreaking additive manufacturing technology designed to produce ceramic components tailored for the cast metals industry. Our Patented system is powered by the ExOne binder jetting platform, renowned for its speed and flexibility in 3D printing, this system revolutionises ceramic foundry consumables production.

Technology Description:Utilising an industrial printhead, the CERACAT System swiftly deposits a liquid bonding agent onto a layer of Pre Sintered Media (PSM), following a precise layer-by-layer deposition process guided by a digital design file. This methodology continues until the desired object is fully formed, resulting in a ‘Green’ part.

Post Treatment:The ‘Green’ part undergoes a critical Post Treatment phase, which can involve Coating, Infiltration, or a combination of both. These Post Treatment processes are custom-tailored to meet specific application requirements, ensuring optimal performance.

Firing Process:The final stage of the CERACAT 3D SYSTEM entails firing the component in a kiln, with temperature settings ranging from 800°C to 1550°C, depending on the application’s demands. Notably, regardless of the firing temperature selected, the component undergoes zero shrinkage, a distinctive feature unique to the CERACAT 3D SYSTEM within the realm of Ceramic 3D printing technologies.

Key Advantages: Patented technology optimised for the cast metals industry. Utilises the ExOne binder jetting platform for rapid and flexible 3D printing. Tailored Post Treatment options for  application-specific customisation. Zero shrinkage during firing, a remarkable feature exclusive to the CERACAT 3D System.

 

  • High in Strength
  • Thermally Stable for steel and heavy iron application temperatures
  • High filtration affinity ie the surface will chemically attract, attach and retain oxide particles
  • Lower relative manufacturing costs
  • Lack of shrinkage during the manufacturing process compared to zirconia enables the cost effective manufacture of very large filters
  • The overall density of the material is higher than Carbon Bonded but lower than zirconia meaning that in direct pour applications the filter floats readily and easily after casting

The CERACAT 3D System utilises 3D printing’s design flexibility to enhance consumable components like Filtration and Gating Systems. It further integrates these components with advanced casting simulation techniques, providing foundry engineers with tools to enhance casting production efficiency and quality to new heights.

Additive manufacturing technology for ceramic foundry consumables.

CERAMIC FILTERS

  • Complete Design Freedom.
  • Consistent High Flow Rates and Capacities.
  • Filtration can now be implemented for larger castings.
  • Fewer Filters needed.
  • Simpler Integration.
  • Lower Environmental Impact – No PU Foam Feedstock being burned out in the manufacturing Process.

Additive manufacturing technology for ceramic foundry consumables.

Key Advantages:

No Compromise: The frustration of every Methods engineer. If you design and simulate an ‘optimal’ filling system there is now no need to compromise implementation.

Complete Design Flexibility: The CERACAT 3D SYSTEM offers limitless design possibilities, allowing for highly customised solutions.

Tooling Free: It eliminates the need for specialised tooling, reducing setup time and costs.

1-off to 1000’s: Whether you require a single unit or mass production, the system is adaptable to varying production volumes.

Lightweight: Typically, CERACAT components weigh only a third of standard ceramic ‘holloware,’ reducing overall weight, transportation costs and ease of setup.

Integration into ‘Standard’ Systems: Seamlessly integrates with existing systems.

Replaces Multiple Piece Assemblies: Simplifies complex structures by replacing multi-component assemblies with a single, consolidated piece.

High Strength: CERACAT components exhibit good strength, ensuring durability and no breakage during set up and ramming the mould.

Reduced Waste: CERACAT parts are environmentally friendly, as they can be reclaimed into the sand system, minimising waste.

Casting trial

  • 80 – 60mm Reduced Double 90 Deg Sweepwith 120 Deg Offset.
  • Male/female joint made to be compatible with standard holloware.
  • Piece weight :1100g.
  • Cast with Low Carbon Steel 1620°C.
  • Bottom Pour Ladle, 2 meter drop to ‘split’.