LONGYI is committed to utilizing cutting-edge advanced ceramic processing techniques and precision manufacturing processes to deliver high-quality ceramic products. Our technologies encompass every stage, from the initial powder preparation of ceramic materials to the final post-processing, ensuring that every detail meets the most stringent standards.
1. Powder Preparation
2. Forming Techniques
LONGYI offer a variety of forming techniques to meet the needs of different ceramic products, with a special emphasis on Ceramic Injection Molding (CIM):
Ceramic Injection Molding (CIM): CIM technology involves mixing ceramic powders with organic binders to form a material that can be injected into molds under high pressure using an injection molding machine. This technology is particularly suitable for producing complex-shaped, high-precision, and high-quality ceramic parts. CIM not only allows for large-scale production but also significantly reduces processing steps and costs, improving production efficiency and product consistency. It is a core technology in our precision ceramic manufacturing.
Press Forming: Using uniaxial pressing or isostatic pressing techniques, ceramic powders are compacted into shape. Isostatic pressing provides uniform pressure, producing high-density, performance-stable compacts.
3. Pre-Sintering Treatment
Before sintering, we carry out debinding to gradually remove organic binders and volatile substances from the compact, preventing defects during the sintering process.
4. Sintering Techniques
Sintering is a crucial step in forming dense solid structures from ceramic powders. We offer a variety of sintering techniques to meet different requirements:
Conventional Sintering: Performed in a high-temperature furnace, this method forms a dense and solid ceramic structure.
Hot Pressing Sintering: Sintering under applied pressure further enhances material density and mechanical properties.
Microwave Sintering: Using microwave energy for rapid sintering, this method is energy-efficient and reduces sintering time.
Atmosphere-Controlled Sintering: Sintering in specific atmospheres (e.g., hydrogen, nitrogen, inert gases) prevents oxidation or other unwanted reactions.
5. Precision Machining
After sintering, we provide industry-leading precision machining techniques to ensure every ceramic product meets the highest standards:
CNC 5-Axis Machining: We utilize advanced CNC 5-axis machining technology, enabling precise machining of complex geometries and achieving high-precision multi-angle cutting. This technology is especially suitable for producing high-precision and complex-shaped ceramic parts, ensuring every detail meets stringent customer requirements. CNC 5-axis machining not only increases processing efficiency but also reduces errors caused by multiple clamping, enhancing product consistency and quality.
Grinding and Polishing: Our grinding and polishing technology achieves nanometer-level surface finishes, a key step in the production of precision ceramic products. Through precise grinding and polishing, we can process sintered ceramic parts to the desired dimensional accuracy and surface quality, meeting the highest industry standards. This technique is particularly suitable for the precision machining of high-hardness ceramic materials, ensuring excellent performance in applications.
Laser Machining: Utilizing high-energy laser technology for precise cutting, drilling, and engraving, suitable for processing complex shapes and fine structures.
6. Precision measurement and Testing
LONGYI rigorously test every product’s performance to ensure it meets the highest standards. Notably, we collaborate with the internationally renowned testing and verification service provider iST (Integrated Service Technology) to further enhance our testing capabilities and accuracy.
Precision Measurement: We employ state-of-the-art measurement equipment and techniques to ensure the dimensional accuracy, surface quality, and geometric tolerances of every product meet the design specifications. Precision measurement covers everything from basic dimensional checks to complex geometric tolerance testing, allowing for accurate evaluation of ceramic parts’ various parameters, ensuring stability and reliability in demanding applications. This process helps identify and correct any production deviations, ensuring every batch of products meets the highest quality standards.
Our collaboration with iST allows us to leverage their leading-edge technology and extensive experience in testing areas such as electronic components, materials science, and failure analysis. iST is known for its superior testing capabilities, high accuracy, and industry leadership, providing us with deeper material analysis and precision testing, further enhancing the quality and reliability of our products.
Physical Performance Testing: Measuring density, hardness, flexural strength, etc.
Microstructure Analysis: Using SEM, TEM, and other equipment to observe the material’s microstructure and defects.
Thermal Performance Testing: Measuring crucial thermal performance indicators such as thermal expansion coefficients and thermal conductivity.
7. Post-Processing and Assembly
LONGYI offer a variety of surface treatment techniques to enhance the performance and applicability of ceramic products, including:
Ceramic Metallization: By depositing a metal layer on the ceramic surface, we endow the ceramic with conductivity or other special properties, suitable for applications such as electronic component packaging and high-temperature environments.
Ceramic Brazing: Using special alloy materials to braze ceramics to metals or other ceramic materials at high temperatures, achieving strong, hermetic bonds ideal for complex structures and high-reliability applications.
Additionally, we provide assembly and packaging services tailored to customer needs, ensuring products remain in optimal condition during transportation.