SHOWCASE
Real projects, real constraints, real numbers
Nine parts that pushed a specific limit of ceramic CIM - and how each one was solved.
Ultra-Thin Wall + A-Grade Gloss, Coexisting
Difficulty: thin-wall parts face the highest risk at demolding and sintering - insufficient support means the green body deforms or breaks easily, while a high-gloss mold also readily traps air or leaves flow marks during injection. Requiring A-grade gloss on top of that stacks two demanding constraints on process control.
Open the full page B · /showcase/micro-hole-array/Dense Micro-Hole Array
Difficulty: 121 holes within a 25mm×3mm area, 0.3mm hole diameter, 0.6mm spacing. Almost no material between holes, demanding extreme fill uniformity - any local density variation deforms hole geometry after sintering. Dry pressing can't achieve this; machining is prohibitively costly and risks cracking the substrate.
Open the full page C · /showcase/deep-cavity/High Depth-to-Diameter Cavity
Difficulty: an internal cavity at roughly 5.2:1 depth-to-diameter demands a great deal from core design and demolding. This ratio describes an open internal cavity with a removable core, not the blind-hole or through-hole ratio limits in the DFM guide. Thermal expansion/contraction during injection means a deep cavity is prone to sticking in the mold; anisotropic sintering shrinkage can slightly distort the cavity geometry, and core-pull stress may damage the green body.
Open the full page D · /showcase/3d-surface/3D Surface + Assembly Mating Face
Difficulty: controlling sintering distortion on a 3D curved surface while holding ±0.05mm on an assembly mating face - these two requirements stacked demand 3D shrinkage-compensation calculations be finished at the mold-design stage, or the curve/plane relationship shifts after sintering. Complex 3D surfaces are also prone to uneven internal cohesion during forming.
Open the full page E · /showcase/black-zirconia/Black Zirconia High-Gloss Part
Difficulty: the TZ-Black colorant and the base zirconia have systematically different sintering behavior, making batch-to-batch color consistency hard to control, and requiring an independent mold-scale factor and process-parameter set - it can't share a mold with white zirconia. Black zirconia powder's color stability is also weaker, so high-gloss mirror finishes readily reveal sink marks, pinholes, color stains, or scratches.
Open the full page F · /showcase/medical-micro/Ultra-Small Precision Medical Part
Difficulty: medical device parts typically demand the combination of very small size and very high precision. A small volume means the injection-fill pressure path is short, raising short-shot risk; the extremely light green body also means minor impacts during handling can cause damage.
Open the full page G · /showcase/alumina-thermal/Alumina Industrial Heat-Sink Part
Difficulty: the base mounting wall is 4.8mm thick, far past the typical 0.7-1.5mm sink-safe range, already carrying elevated internal-porosity risk; at a 4.8:1 wall-thickness ratio, the open-frame structure also amplifies distortion risk from green-body density gradients during sintering. Two factors stacked to push warpage risk to an extreme. At a more microscopic material level, alumina's own particle size runs larger than zirconia's and its particle-size distribution is less uniform, which makes sintering shrinkage itself less consistent - a third layer of cause stacked on top of the structural factors. This is the real project documented in WP-05 - three gate-plan iterations, from 0% to 100% yield.
Open the full page H · /showcase/dual-color/Black/White Dual-Color Matched Pair
Difficulty: the black and white versions of the same product are geometrically identical, but the two zirconia colors shrink differently and must be tooled separately - black zirconia is white zirconia with an added colorant oxide, and different colorants carry cross-contamination risk plus different particle sizes that change crystallization behavior and sintering shrinkage. At equal geometric volume, black weighs 8-10% more than white.
Open the full page I · /showcase/porosity-improvement/Internal-Wall Porosity Improvement
Difficulty: a precision structural part showed elevated internal-wall porosity early in development - an initial porosity of 5.0%, affecting internal densification and structural reliability.
Open the full page