[3D Printing Applications] A Revolution in the Ceramic Industry: 10% Cost, Five Times the Capacity!

[3D Printing Applications] A Revolution in the Ceramic Industry: 10% Cost, Five Times the Capacity!

Průmyslovákeramika, a well-known Central European company specializing in ceramic blends and custom-made heat-resistant parts, transformed its traditional production processes in 2016 and began using the Ultimaker 3D printer to manufacture mold components. This increased the manufacturing speed of heat-resistant mold cavities by five times, reduced production costs to 10% of the original cost, and ensured perfect repeatability.

"Průmyslovákeramika," meaning "industrial ceramics" in English, was founded in 1991. With 75 employees, it produces over 9,500 tons of ceramic mixtures and nearly 1,600 tons of structural parts annually, generating an annual turnover of 220 million Czech crowns (US$9.8 million). Their success hinges on rapidly fulfilling customer requests. However, each order for ceramic parts is unique, requiring distinctive mold designs. Therefore, they must utilize additive manufacturing to meet the substantial customization demands, leading them to choose the Ultimaker 3D printer .



Tailor-made precision industry

These molds are typically shaped with a stainless steel shell, into which a central core is inserted to define the internal function and details of the part, such as grooves, holes, and curves. These fittings are often complex shapes that must be designed and manufactured to precise specifications provided by the customer. In the past, these internal modules were made using handcrafted woodwork or CNC metal inserts; a single woodwork fitting could cost up to 20,000 Czech crowns (US$895) and take more than 30 hours to carve, making it both time-consuming and expensive.


(The image shows a ceramic refractory material part, a finished product made from a steel shell and a 3D printed mold core.)

In 2013, they began experimenting with 3D printing to accelerate mold production, but their first 3D printer encountered problems. "We tried to overcome the various issues of inconsistent print quality, and at that time only about 30% of prints were successful; the rest were waste," said Jakub Cvilinek, the company's general manager. Despite this experience, they still believe in 3D printing technology. "This technology remains indispensable to us, even though we chose an unsuitable 3D printer at the time."

Mold making process revitalized: Ultimaker 3D printer

Until 2016, they found the Ultimaker 3 Extended 3D printer . Finally, the company found a robust and professional 3D printing machine. Two years later, Jacobs added the new Ultimaker S5 , which, in addition to perfect print quality, boasted a simpler user interface and larger print volume. As the team used 3D printing to create mold cores and other mold components, the advantages of the technology became apparent: accuracy, speed, and repeatability—plus greater creative freedom in part design, and most importantly, it was significantly cheaper than previous processes.


(The photo shows Jack Bo, General Manager of Průmyslovákeramika, with his production assistant , Ultimaker S5 .)

For 3D printing mold cores, they use only PLA material because it is easy to use and has a low melting point and glass transition temperature. Since many core structures are embedded in the ceramic material until the firing process begins, the specially formulated PLA material can be completely melted from the mold when the firing temperature exceeds 900°C, resulting in a high-quality hollow cavity. Currently, only two operators are needed to supervise the 3D printers producing the parts, while components are designed by the engineering department using Autodesk Inventor and AutoCAD, allowing for quick and easy modifications.
(Further reading: The secrets of 3D printing to lost-wax casting: PolyCast )

Industrial transformation is imperative.

" The Ultimaker 3 Extended and S5 not only save us significant production time and costs, but also enable us to produce shapes that were previously impossible! With technological advancements, 3D printers will become indispensable production tools," said Jake Burr. 3D printing has become a crucial asset in the company's manufacturing process, producing parts approximately five times faster and ten times cheaper than traditional methods. For example, the material used for the mold core of the air and gas mixer in a 3D-printed industrial burner costs only 300 Czech crowns (US$13.43). This means that in just a few months, their cost savings exceed the return on investment of their initial purchase of the Ultimaker 3D printer .


(The image shows a 3D- printed blade mold , which allows for greater design freedom and easier demolding.)

In addition to reducing reliance on CNC milling, the company also saves on production costs associated with repeated modifications, benefiting from local manufacturing, rapid prototyping, and the ability to repeat production simply by reprinting files when necessary.

3D printing allows for more complex shapes and greater design freedom .

For Průmyslovákeramika, the addition of the Ultimaker 3 and Ultimaker S5 has completely transformed their manufacturing process. They are now confident in their ability to meet and even exceed customer expectations in terms of quality.
Jakeber emphasized, "In the past, some particularly complex mold core shapes were impossible to manufacture, and some traditional methods were too expensive; but now, we can produce them ourselves using the Ultimaker 3D printer ."
(Further reading: Metal parts here! A collection of 3D printing and casting! )

Do these production processes resemble your experience? Benefit from these advantages now with Ultimaker 3D printers and create your business success story. SanTima offers excellent print quality and original equipment manufacturer (OEM) machines. We believe that print quality determines product value. Contact us to learn more about industrial-grade 3D printers .

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