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Complex Shape Forming Technology:
F-Molding

Complex Shape Forming Technology: F-Molding

New solution for achieving complex shapes while reducing raw material waste

Slurry conditioned material is casted into product-shaped mold and formed by solidification.
This is Kyocera's new forming method which enables near-net shapes, and is expected to expand ceramics' applications further.
Parts developed via F-Molding have the same or better characteristics compared to those produced by CIP (Cold Isostatic Pressing) forming.

Features

  • Unique and Complex Shaped Part FormingAchieves complex designs which can not be achieved by conventional green machining and grinding.
  • Near-Net Shape FormingCost savings achieved by reducing material waste with less machining (compared to CIP forming)
  • Small Volume Orders AvailableInitial cost saving with less expensive mold (compared to injection molding and press forming)

Design Samples

  • Material: Zirconia (ZO 206 N) Size: Φ 50 mm
  • Material: Zirconia (ZO 206 N) Size: Φ 50 mm

Material: Zirconia (ZO 206 N) Size: Φ 50 mm

  • Material: Silicon Nitride (SN 240 O) Size: Φ 50 mm
  • Material: Silicon Nitride (SN 240 O) Size: Φ 50 mm

Material: Silicon Nitride (SN 240 O) Size: Φ 50 mm

*Please ask us about available sizes.

Manufacturing Process

Conventional Method

CIP forming +
Green machining

RAW MATERIAL
Arrow
FORMING
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GREEN MACHINING
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SINTERING
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GRINDING
SPRAY DRYING
Forming a cylindrical ceramic block

Forming a cylindrical ceramic block

Green Machining into shape

Green Machining into shape

After sintering, final grinding

After sintering, final grinding

New Method

F-Molding

RAW MATERIAL
Arrow
FORMING
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SINTERING
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GRINDING
SLURRY PREPARATION
MOLD PREPARATION
Molding into near-net shape

Molding into near-net shape

  • No green machining process
  • Arrow
  • ・Reduction of raw material waste
    ・Reduction of processing time
After firing, final grinding

After firing, final grinding

Material Lineup

Material
Material Code
Zirconia Cordierite Silicon Nitride
ZO206N CO220O CO720O SN240O
Color - White Gray Gray Black
Density g/cm3 6.0 2.5 2.5 3.3
Mechanical Characteristics Vickers Hardness HV9.807N GPa 12.0 8.0 8.5 14.0
Flexural Strength (3-point Bending) MPa 1,100 190 200 1,020
Young’s Modulus GPa 210 140 145 300
Poisson’s Ratio - 0.32 0.31 0.31 0.28
Fracture Toughness (SEPB) MPa・m1/2 6-7 1-1.5 1-1.5 7
Thermal Characteristics Coefficient of Linear Thermal Expansion 40-400℃ × 10-6/K 10.4 (*) 1.5 (*) 1.5 2.8
40-800℃ 10.8 (*) 2.1 (*) 2.1 3.3
Thermal Conductivity 20℃ W/ (m・K) 3 4 4 27
Specific Heat Capacity J/ (g・K) 0.44 0.71 - 0.65
Thermal Shock Resistance
(quenching into water)
350 - 400 800

* <|0.05|(23℃)、<|0.02|(22℃)

Materials not listed in the table are under development, please feel free to contact us for further information.

Values are based on typical material properties and
may vary according to product configuration and manufacturing process.