Ceramic Injection Moulding Capabilities

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1 Ceramic Injection Moulding Capabilities TECHNICAL CERAMICS

2 About is a global materials engineering company which designs and manufactures a wide range of high specification products with extraordinary properties, across multiple sectors and geographies. From an extensive range of advanced materials we produce components, assemblies and systems that deliver significantly enhanced performance for our customers products and processes. Our engineered solutions are produced to very high tolerances and many are designed for use in extreme environments. The Company thrives on breakthrough innovation. Our materials scientists and applications engineers work in close collaboration with customers to create outstanding, highly differentiated products that perform more efficiently, more reliably and for longer. has a global presence with over 9,000 employees across 50 countries serving specialist markets in the energy, transport, healthcare, electronics, security and defence, petrochemical and industrial sectors. It is listed on the London Stock Exchange in the engineering sector. Why Ceramic Injection Moulding (CIM) should be considered CIM offers a solution when part complexity goes beyond the boundaries of more basic forming technologies such as dry pressing. This allows engineers greater versatility and freedom in designing components that previously would have been deemed as too difficult or expensive to manufacture. Ceramics have significant advantages characterised by their outstanding physical, chemical, mechanical, thermal and/or electrical properties. Global Technical Support and Customer Service With a world-leading reputation and manufacturing sites on three continents, our sales and technical support network provides assistance throughout the product design and development process, from prototyping to full production. This enables us to provide the structure and capability to work with global businesses at national and international level. Whilst our quality systems ensure adherence to specifications and full traceability.

3 What is Ceramic Injection Moulding? The CIM process begins with very fine ceramic powders. The powders are compounded with polymer binders to produce a pelletised feedstock. During moulding, binders melt to form a liquid medium that carries the ceramic powders into the mould during the injection stage. Using an injection moulding machine similar to that used in conventional plastic moulding, the feedstock is forced into a mould cavity forming a net shape part. Moulds can be single-cavity or multi-cavity configurations. After forming, the part goes through a two-stage process. First is pyrolysis or debinding to remove the binder, followed by sintering in a high temperature kiln to form a fully dense ceramic component. During sintering the component shrinks uniformly by as much as 20% while retaining the complex shape. With good process control, it is possible to achieve a uniform and repeatable shrinkage leading to tight tolerances, reducing the likelihood of requiring additional processing afterwards. Materials: Morgan offers a range of high performance materials formulated specifically for the CIM process. The materials have been designed in line with our customers requirements to give optimal characteristics in challenging applications. Materials we work with include: Hilox 998 (99.5% Alumina) Yttria stabilised Zirconia Zirconia Toughened Alumina (ZTA) The benefits of CIM Accommodates extremely complex geometric components Provides unique, economic solutions to increasingly stringent material and product design requirements Excellent batch to batch repeatability and process capabilities achieving a tolerance of +/ <0.5% High surface finish quality without the need for additional finishing processes Excellent batch to batch repeatability with exceptional process capabilities Can be used for metallised applications Superior material performance, high hardness and mechanical strength, wear, corrosion and weathering resistant, dimensionally stable, high working temperature and good electrical insulator Economies of scale available include macro and micro sized components Silicon Nitride Custom Developed Materials Typical Applications: Diagnostic Equipment Flow sensors and meters Fluid and power handling Mass Spectrometry Oil well submersible pumps RF ablation instruments Surgical instruments Valves and bearings

4 TECHNICAL CERAMICS Tools paramount to the success of the CIM process Moldflow Analysis conducts Moldflow simulation and analysis in order to optimise the part and mould design. On the computer, adjustments are made to gate positions, wall thickness, gate positions and cooling parameters to help achieve success. By performing this analysis early in the design process, many problems can be addressed and improvements can be implemented quickly at low cost and without causing expensive delays in the production schedule. Tool Design Today cost is an increasingly important consideration; CIM offers virtually endless solutions for delivering repeatable, ultra high precision ceramic components. Engineers need versatility and flexibility when designing advanced components and one of the main benefits is that it allows for designs that previously may have been too difficult or expensive to manufacture with other materials, to become commercially viable. Morgan Advanced Materials can design injection moulding tools with single or multiple impressions, over a wide range of scales; from macro to micro sized components to suit our customers requirements. Rapid Prototyping In the ever changing and evolving business environment the constant need to reduce the time it takes to bring a new product to market is recognised by Morgan. We work with our customers from the initial concept to a final differentiated design solution. Our rapid prototyping service can be used during the development phase of each project to ensure our customers receive an optimised cost effective product. Rapid prototyping is one tool we have to support a fasttrack path from concept to production samples.

5 TECHNICAL CERAMICS CIM Production Process 3D Computer Generated Model (used for feasibility study) Prototypes (CNC machined directly from 3D model) Mould Tool Manufacture (Moldflow analysis if required) Case Study: Ablation Tips CIM Process Metrology & Validation (Direct comparison to model) Production Sign Off With Customer Project Management With over 10 years of ceramic injection moulding experience, our dedicated team of specialist sales, customer service and application engineering staff, will work with our customers at every stage of the project. From concept through to development, commercialisation and finally production scale manufacturing, we believe that working closely with our customers is key to ensuring a project is delivered successfully. A precision engineered tip made by Morgan Advanced Materials is being used in a new treatment to ablate tumours. The minimally invasive procedure means that patient trauma following surgery is reduced and post operation recovery times are significantly shorter. 70% reduction in hospital recuperation time.

6 TECHNICAL CERAMICS MORGAN ADVANCED MATERIALS LISTED ON THE LONDON STOCK EXCHANGE SELLING INTO >100 COUNTRIES OVER 9000 EMPLOYEES MANUFACTURING IN >30 COUNTRIES For all enquiries, please contact our specialist sales and manufacturing sites: Europe North America South America Asia Morgan Drive Stourport-on-Severn Worcestershire DY13 8DW United Kingdom 4000 Westchase Boulevard Suite 170, Raleigh, NC USA Avenida do Taboão São Bernardo do Campo SP CEP Brasil 150 Kampong Ampat 05-06A KA Centre Singapore T +44 (0) F +44 (0) [email protected] T +1 (855) F +1 (706) [email protected] T +55 (11) F +55 (11) [email protected] T F [email protected] Visit our website Follow us on twitter.com/morganadvanced Follow us on facebook.com/morganadvancedmaterials Follow us on linkedin.com/company/morgan-advanced-materials plc Quadrant, High Street, Windsor, Berkshire, SL4 1LP United Kingdom Copyright Designed and Produced by Reflection Design