Continuous Production Process for 3D Printed Ceramic Foundry Filters 

Another key benefit of the AM process is scalability. Meeting an increasing demand for large-format components, such as the offshore wind turbine market, is constrained by current processes. “Our technology enables us to increase a filter’s flow rate and capacity. Manufacturing something like a wind turbine requires more and more metal through filters. AM offers the potential to reconfigure a filter and create something bespoke for these newer applications,” says Leaney. 

One of the problems with 3D printing ceramic is shrinkage during firing. Building on CAT International Ltd’s earlier ceramic innovations, the project team developed a novel formulation containing pre-sintered material for printing, followed by a coating to strengthen the final structure. “The result is a ceramic that doesn’t shrink, doesn’t affect pore size, and is strong enough to handle metal at 1700 degrees.” 

AM production of ceramic parts is still in its infancy and is constrained by the capital cost of large-scale 3D printing equipment. However, Leaney believes the pace of development around this technology, coupled with increasing usage applications, could revolutionise the industry. “It’s not just filters; foundries could produce other ceramic parts they require but are currently importing, such as gating. The technology has potential applications for the ceramics industry, too, such as commercial potteries,” he says. “These sectors use high volumes of raw material and increasing amounts of energy – our technology can potentially improve their environmental performance and bottom line.” 

“3D-printing gives us complete control over the cellular structure – shape, pore size and flow path – so a filter can be engineered to improve performance and efficiency.”