Product Descriptions
Case Study Approach in Ceramic Injection Molding
Ceramic Injection Molding (CIM) is an advanced manufacturing technology in which very fine ceramic powders are compounded with binder systems, shaped by injection molding, and subsequently converted into dense ceramic parts through debinding and sintering. CIM is widely used for components that are difficult, costly, or technically impossible to manufacture using conventional pressing or machining processes.
This technology is particularly suitable for:
- Micro and high-precision ceramic components
- Extremely tight tolerances
- Complex geometries
- High mechanical, thermal, and electrical performance requirements
Dr.BOY injection molding machines provide a reliable production platform for CIM applications thanks to their high process stability, precise dosing capability, and vibration-free mechanical design, which are essential for ceramic powder feedstocks. The following case studies are based on real production examples and are supported by detailed technical and numerical data.
Case Study 1 - Al2O3 Technical Ceramic Pin Production
Application Description
Production of small, high-precision ceramic pins made from Al2O3 technical ceramic material. After sintering, the parts are designed to offer high hardness and excellent wear resistance for technical applications.
Technical Data
Part type: Pin
Material: Al2O3 technical ceramic
Green part weight: 0.27 g
Sintered part weight: 0.18 g
Shot weight: 1.94 g
Machine: BOY 12 A
Screw diameter: 14 mm
Cycle time: 20 s
Number of cavities: 4
Runner system: Sprue pin, runner, and gating system
Process Challenges
Limited flowability due to high ceramic powder content, balanced filling of four cavities, and control of green part fragility were the main challenges of this application.
Dr.BOY Advantage
Precise injection control and vibration-free machine mechanics enabled homogeneous filling of the ceramic feedstock, resulting in crack-free and segregation-free green parts.
Case Study 2 - Zirconia (ZrO₂) Micro Planetary Gear Step
Application Description
Production of a zirconia-based ceramic planetary gear step used in micro-mechanical and precision drive systems. This part requires extremely tight tolerances, particularly with respect to axis parallelism.
Technical Data
Part type: Planetary gear step
Material: CIM zirconium oxide (ZrO₂)
Final part weight: 0.127 g
Green part weight: 0.153 g
Shot weight: 0.73 g
Machine: BOY 35 A - 15
Screw diameter: 14 mm
Cycle time: 22 s
Number of cavities: 1
Runner system: Pin gate (Stangenanguss)
Process Challenges
Complete filling of micro-scale gear teeth, preservation of axis parallelism in the green part, and achievement of dimensional accuracy after sintering were critical process risks.
Dr.BOY Advantage
High injection precision and stable clamping force enabled production of micro ceramic gears with extremely low tolerances and excellent surface integrity.
Case Study 3 - Large-Volume Porcelain Cup Produced by Injection Molding
Application Description
Manufacturing of a large, single-piece porcelain cup using ceramic injection molding. This application demonstrates that CIM is not limited to micro components but can also be applied to larger ceramic products.
Technical Data
Part type: Cup
Material: Porcelain
Green part weight: 175.7 g
Shot weight: 175.7 g
Machine: BOY 90 A
Screw diameter: 42 mm
Cycle time: 42 s
Number of cavities: 1
Runner system: Heated hot runner with shut-off needle
Process Challenges
Uniform filling of a high-volume ceramic feedstock, prevention of sink marks and deformation, and safe demolding of a large green part were the main challenges.
Dr.BOY Advantage
High mechanical rigidity and controlled injection behavior allowed the large porcelain component to be produced without deformation and with uniform wall thickness.
Overall Evaluation - Results from CIM Case Studies
These ceramic injection molding case studies clearly demonstrate the strengths of Dr.BOY injection molding machines in CIM applications:
- Compatibility with Al2O3, zirconia, and porcelain ceramic feedstocks
- Wide application range from micro parts to large ceramic components
- Stable filling in both multi-cavity and single-cavity molds
- Reliable preservation of green part integrity
- High dimensional accuracy and surface quality after sintering
Conclusion - Why Choose Dr.BOY for Ceramic Injection Molding?
Dr.BOY injection molding machines represent more than standard production equipment for ceramic injection molding. They provide a powerful engineering platform for high-precision, repeatable, and reliable ceramic part production. These real industrial case studies clearly demonstrate why Dr.BOY is a preferred solution for CIM applications across technical, industrial, and advanced ceramic markets.
