CARBOPRINT™
With Carbon into
New Dimensions
Additive Manufacturing
with Carbon Materials
and Post-Processing
Technologies
2
With carbon into new dimensions
– made by SGL Group
SGL Group – The Carbon Company – is a
leading global manufacturer of carbonbased products. We have wide-ranging
expertise in raw materials, advanced manufacturing processes, and longstanding
application and engineering know-how.
Focusing on the technological challenges
of megatrends, like digitalization and
individualization, we develop innovative
carbon based solutions. With additive
manufacturing we open new dimensions
in respect to product design, performance
and time-to-market.
Additive manufactured carbon components
3
CARBOPRINT™ – Additive manufacturing with carbon materials
and post-processing technologies
Classical carbon based components are made by machining, which is a
standard “subtractive” process. In contrast, additive manufacturing,
such as 3D printing, is an innovative, material efficient, layer by layer
process. It opens up new dimensions of design freedom.
Together with our partners and customers we develop individual and new
out of the box solutions for tomorrow.
The CARBOPRINT family combines our
comprehensive carbon material knowhow with additive manufacturing
technology. In addition, our broad base
of post-processing capabilities, such
as metal, resin or silicon infiltration,
CARBOPRINT M
delivers innovative material solutions
Metal carbon
composites
for your applications.
This set of competencies and capabilities is a unique starting point for rapid
and economic production of prototypes
Metal
infiltration
and small series of carbon based components for various industries such
as glass, metal and chemicals, as well
as high-temperature and mechanical
applications.
CARBOPRINT C
CARBOPRINT P
Polymer carbon
composites
CARBOPRINT material family a
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Carbon and graphite
CARBOPRINT Si
Ceramic carbon
composites
4
Additive manufactured carbon components
5
Benefitting from unique carbon properties
and additive manufacturing technology
Advantages of additive manufacturing with binder jetting
Advantages of using carbon in additive manufacturing
technology
̤̤ Carbon and graphite specific properties (e. g. low weight,
̤̤ Complex design at no additional cost (e. g. realization of
undercuts and/or cavities)
electrical and thermal conductivity, mechanical strength,
chemical and high-temperature stability, low thermal
̤̤ Acceleration of developments and production launch of
expansion)
̤̤ Porous body structures deliver ideal basis for new
small series
̤̤ Use of materials suitable for industrial applications
̤̤ Capabilty to produce large industrial components
material designs via metal, polymer or silicon infiltration
̤̤ Intelligent functions are possible (e. g. heating and thermal
management)
Post-processing
Types
Typical properties
Potential components
None/
Carbon infiltration
CARBOPRINT C
Q Low density
Q Open porosity
Q Isotropic homogenous structure
Q Casting cores
Q Casting molds
Q Preforms
Polymer infiltration
CARBOPRINT P
Q Complex designs with improved
mechanical properties
Q Accelerated development
Q Good gliding properties
Q Electrical contacts
Q Gliding elements
Q Pump parts
Q Electrodes
Q Heat exchanger components
Q Heaters
Q Sealings
Metal infiltration
CARBOPRINT M
Q High strength at elevated
temperature
Q Good electrical and
thermal conductivity
Q Casting molds
Q Bearings
Q EDM electrodes
Silicon infiltration
CARBOPRINT Si
Q High hardness – low wear
Q High temperature resistance
Q Good corrosion resistance
Q Pump impellers and casings
Q Burner nozzles
Q Heat exchangers
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CARBOPRINT™ C
Carbon and graphite components
Carbon and graphite powders are the basis for
cost-efficient serial production of carbon and
Freedom of
(material)
design
graphite based components. Their porous bodies
are binded with chemically and thermally stable
duroplastic binder systems – all with help of
SGL Group‘s established processes and know-how.
The highly porous carbon structure of
CARBOPRINT C bodies is an ideal basis for
CARBOPRINT C
post-processing, such as infiltration with silicon,
or impregnation with polymers and metals.
Processable
like additive
manufacturing sands
Lightweight –
low density,
open porosity
b Carbon powder as the basis material
d Porosity of printed carbon delivers ideal basis for refinement
Typical material data for our CARBOPRINT™ C
Typical properties
Units
C1
Density
g/cm³
1.0
%
40 – 50
Open porosity
E-modulus
GPa
2
Flexural strength
MPa
5
Ωµm
125000
Electrical resistivity
Thermal conductivity
CTE (at RT/150 °C)
W/(mK)
<1
µm/(mK)
5.5
Additive manufactured carbon components
7
CARBOPRINT™ P
Polymer carbon composites
Lightweight
Porous carbon
structure and
low weight resins
Heating functions
Thermal properties
of carbon and
resins
Electrical and
thermal conductivity
Adjustable and high
conductivities possible
CARBOPRINT P
Temperature
stability
Heat resistant < 200 °C
CTE
CTE lower than
pure polymers
New material
designs
Infiltration of carbon
with polymers, i. e. resins
Applications that require non-metallic materials will
profit significantly from polymer carbon composites.
This material is temperature resistant up to 200 °C –
without creeping effects common among other
polymers. Depending on the choice of polymer,
properties such as mechanical or chemical stability
can be adjusted to customer requirements.
a Choice of polymer increases
material design variability
d Sample part infiltrated with polymers
Typical material data for our CARBOPRINT™ P
Typical properties
Units
P1
P2
Density
g/cm³
1.58
1.4
E-modulus
GPa
6
6
Flexural strength
MPa
15
45
100000
Electrical resistivity
Thermal conductivity
CTE (at RT/150 °C)
Ωµm
35
W/(mK)
40
<1
µm/(mK)
12
40
8
CARBOPRINT™ Si
Ceramic carbon composites
Lightweight
Low density due to
porous carbon
structure and silicon
Established
manufacturing
Key know-how in
post-processing,
i. e. infiltration
Ceramic carbon composites provide ideal
properties when it comes to reliable function
and longevity in harsh environments and at
high temperatures.
We bring decades of experience with ceramic
Chemical stability
Good oxidation and
chemical resistance
CARBOPRINT Si
Temperature
resistance
Up to 1200 °C and
against thermoshocks
composites to additive manufacturing, in order to
provide our customers the opportunity to realize
almost any design with ceramic carbon composites.
CARBOPRINT SI components are made by siliconizing CARBOPRINT C bodies.
Low CTE,
high precision
High hardness
Strong resistance
against abrasion
c Silicon used in our
infiltration process
d Pump impeller in CARBOPRINT Si
Typical material data for our CARBOPRINT™ Si
Typical properties
Units
Density
g/cm³
Si1
2.3
Open porosity
Vol.-%
<0.1
E-modulus
GPa
35
Flexural strength
MPa
60
Elongation at break
%
0.25
Bending energy absorption
Nmm
Electrical resistivity
Ωµm
340
20
W/(mK)
50
Thermal conductivity
µm/(mK)
3
Silicon carbide content
wt.-%
25
Silicon free content
wt.-%
35
Carbon content
wt.-%
40
CTE (at RT/200 °C)
Additive manufactured carbon components
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CARBOPRINT™ M
Metal carbon composites
Metal carbon composites are designed for purposes
where the combination of metal and carbon
Simplicity
No specialized
metal powder
necessary
properties are needed.
They are suitable for applications in elevated
temperature environments, where good electrical
conductivity and/or where low friction is needed.
Lightweight
Lower density
than that of
pure metals
Lower wear
Good gliding
properties
CARBOPRINT M
Thermal & electrical
properties adjustable
combining carbon and
metal advantages
CTE
Lower CTE
than pure metals
Flexibility
Available choice
of metals depending
on component function
b Antimon for metal impregnation
d Sample parts in CARBOPRINT M
Typical material data for our CARBOPRINT™ M
Typical properties
Units
M5
Density
g/cm³
3.0
E-modulus
GPa
23
Flexural strength
MPa
20
Ωµm
µm/(mK)
5
6
Carbon content
Vol.-%
60
Metal content
Vol.-%
30
Pores
Vol.-%
10
Electrical resistivity
CTE (at RT/200 °C)
10
Additive manufacturing technology and
post-processing expertise combined
From individual requirements to customized solutions.
Project initiation
Binder jetting technology
̤̤ Understanding the application requirements
̤̤ Processing the order with partner
̤̤ Connecting customer’s design needs with material
̤̤ On-demand order management or long-term production
specifications
̤̤ Integrating additive manufacturing expertise and design
̤̤ Selecting composite and related post-processing options
with resin, silicon or metal impregnation
c Additive manufacturing process (binder jetting) – building up the carbon
body layer-by-layer
c Customer design file in 3D-CAD format (source: ExOne GmbH)
CARBOPRINT™ family: typical material properties at a glance
Typical properties
Units
CARBOPRINT C
CARBOPRINT Si
CARBOPRINT P
CARBOPRINT M
Density
g/cm³
1.0
2.3
1.4 – 1.6
3.0
E-modulus
GPa
2
35
6
23
Flexural strength
MPa
5
60
15 – 45
20
5
Electrical resistivity
Thermal conductivity
CTE (at RT 150 /200 °C)
Ωµm
125000
20
35 – 100000
W/(mK)
<1
50
<1 – 40
µm/(mK)
5.5
3
12 – 40
6
Additive manufactured carbon components
11
If you want to combine the unique properties of carbon and
We encourage industrial partners with “pioneer” spirit, such
graphite with the advantages of additive manufacturing tech-
as engineers and designers, to develop innovative carbon-
nology, SGL Group will be your partner of trust.
based components with us to gain a significant competitive
Our start into this new era of manufacturing has just begun.
advantage. Join us on the discover journey to new carbon
based dimensions!
Post-processing steps
̤̤ Product refinement
̤̤ Infiltration with polymer or metal or silicon
̤̤ Finishing
̤̤ Delivery
c Polymer infiltrated part
c Metal infiltrated rings
c Silicon infiltrated pump impeller
Additive manufacturing of carbon
CARBOPRINT C
Optional: carbonization/redensification/graphitization
Polymer infiltration
Metal infiltration
Silicon infiltration
Polymer carbon composites
CARBOPRINT P
Metal carbon composites
CARBOPRINT M
Ceramic carbon composites
CARBOPRINT Si
Contact
SGL CARBON GmbH
Werner-von-Siemens-Strasse 18
86405 Meitingen/Germany
Phone +49 8271 83-3523
[email protected]
™ pending trademark application of SGL CARBON SE
01 2016/1 E Printed in Germany
This information is based on our present state of knowledge and is intended to provide general notes on our
products and their uses. It should therefore not be construed as guaranteeing specific properties of the products described or their suitability for a particular application. Any existing industrial property rights must be
observed. The quality of our products is guaranteed under our “General Conditions of Sale”.
Technology & Innovation
SGL CARBON GmbH
Werner-von-Siemens-Strasse 18
86405 Meitingen/Germany
www.sgl-carboprint.com