Complex structural components of porous and multi convex zirconia ceramics

Porous and multi convex zirconia ceramic complex structural components are high-performance special ceramic parts prepared using advanced additive manufacturing (such as 3D printing) or precision injection molding technology. It integrates the inherent excellent properties of zirconia ceramics with carefully designed complex macroscopic/microscopic structures, breaking through the limitations of traditional ceramic processing techniques.

Core material: High purity zirconia (ZrO ₂)
Excellent mechanical performance: It has extremely high hardness, wear resistance, and compressive strength, far exceeding most metals and engineering plastics.
Unbelievable toughness: Thanks to the “phase transition toughening” mechanism, zirconia is one of the most resilient advanced ceramics, effectively overcoming the traditional impression of high ceramic brittleness and exhibiting excellent fracture resistance.
Excellent thermal stability: resistant to high temperatures and thermal impacts, able to maintain size and performance stability in high temperature environments.
Excellent chemical inertness: corrosion-resistant, acid and alkali resistant, compatible with many active chemicals, and has a long service life.
Low thermal conductivity and electrical insulation: It is an excellent thermal barrier and electrical insulation material.
Core Structure: “Porous” and “Multiple Protrusions”
Porous structure: The internal or surface of the component is designed with controllable pore size, porosity, and permeability. This not only achieves lightweighting, but also provides an ideal three-dimensional space for fluid passage, catalyst loading, cell growth, and more.
Multi convex structure: features such as protrusions, tenons, hooks, etc. that are precisely designed on the surface or inside, used for mechanical interlocking, enhancing connections, increasing specific surface area, or achieving specific functions such as mixing and support.
In summary, this product is a perfect example of combining excellent materials with innovative structures, aiming to solve technical challenges that traditional materials cannot cope with.

Product Application and Problem Solving
This unique product, due to its comprehensive advantages, has become a key component in multiple high-end technology fields, directly solving the following core problems:

1. Aerospace and high-end manufacturing fields
   Problem solving: Traditional metal components are prone to deformation and oxidation failure in extreme high temperature and high wear environments; Polymer materials cannot withstand high temperatures.
   Application Scenario:
   High temperature gas filter/seal: Utilizing its high temperature resistance, porous and breathable characteristics, it is used for gas filtration in the hot end of turbine engines, ensuring pure airflow while not melting or oxidizing itself.
   Lightweight structural support: The porous design significantly reduces weight while ensuring sufficient strength, meeting the lightweight requirements of aerospace vehicles for “Kekeqiao”.
   Wear resistant lining plate and guide rail: Under high temperature and no lubrication conditions, their ultra-high wear resistance can significantly extend equipment life and reduce maintenance downtime.
2. Chemical and biological environmental protection fields
   Problem solving: A material that can withstand highly corrosive media and provide a large specific surface area for reaction or filtration is needed.
   Application Scenario:
   Structured catalyst support: The porous three-dimensional network provides a huge loading area and excellent mass transfer channels for catalytic active substances (such as noble metal nanoparticles), greatly improving the efficiency of catalytic reactions.
   High performance filter membrane and distributor: used for precise filtration, separation, and uniform distribution of fluids in harsh environments (strong acids, strong bases, high temperatures), with a lifespan far exceeding that of metal sintered mesh and polymer filter cartridges.
   Biofilm reactor packing: In wastewater treatment, its porous surface is an ideal carrier for microbial attachment, which is conducive to the formation of highly active biofilms and improves wastewater treatment efficiency.
3. Medical and life science fields
   Problem solving: An orthopedic implant that combines biocompatibility, mechanical strength, and a microstructure conducive to cell growth is needed.
   Application Scenario:
   Bone tissue engineering scaffold: imitates the porous structure of human bone trabeculae, providing growth space and attachment points for new bone cells, promoting bone integration, and achieving a firm bond between implants and natural bone. The biological inertness of zirconia ensures extremely high safety.
   Drug sustained release carrier: Controllable pores can be used to load drugs and achieve long-term, stable slow release in the body.
4. New energy and semiconductor fields
   Problem solving: In precision manufacturing and energy conversion, functional components with insulation, high temperature resistance, and dimensional stability are required.
   Application Scenario:
   Fuel cell electrodes/separators: utilizing their ion conductivity (under specific conditions) and high-temperature stability.
   Semiconductor processing fixture: used for ceramic chucks, arms, etc. in wafer transfer, etching and other processes. Its high hardness ensures no particle generation and electrical insulation ensures process safety.

customized service
We are well aware that standard products often cannot meet the needs of all cutting-edge applications. Therefore, we provide comprehensive and in-depth customized services, collaborate with customers for innovation, and provide full support from concept to mass production.

1. Collaborative structural design
   Our engineering team will work closely with you to optimize the macroscopic appearance, internal porous structure (porosity, pore size and distribution, connectivity), and layout and shape of protruding features of the components based on your specific functional requirements (such as fluid mechanics, mechanical load-bearing, thermal management).
2. Material formula customization
   In addition to standard zirconia, we can also adjust the ceramic slurry formula, such as adding other oxides to adjust its thermal expansion coefficient, conductivity, or color to meet special application scenarios.
3. Precise control of performance parameters
   We can precisely control the key performance indicators of the final product, including:
   Porosity: Adjust from 20% to 80% or even higher.
   Aperture size: customized from micrometer to millimeter level.
   Mechanical strength: Optimize the structure according to the load-bearing requirements to achieve the optimal strength weight ratio.
4. Post processing and connection scheme
   We provide various post-processing services such as grinding, polishing, and metallization. Especially providing professional connection solutions (such as brazing and bonding) for “multi protrusion” structures, ensuring their reliable integration with other components.

Our goal is not only to be a supplier, but also a partner for you to solve complex engineering problems. No matter how unique your needs are, we are committed to providing the most matching and reliable zirconia ceramic complex structural component solutions.

Brudeze Ceramics supplies and sells a wide range of high-quality quartz glass, including alumina ceramics, zirconia ceramics, silicon nitride ceramics, aluminum nitride ceramics, silicon carbide ceramics, boron carbide ceramics, bioceramics, machinable ceramics, etc. We can meet the customization requirements of various ceramic products.