BCE participates together with companies, universities and research institutes in selected development and research projects.
The focus is on ceramic materials, demanding component geometries and manufacturing processes that cannot be adequately mastered with existing solutions. The findings gained are incorporated into material selection, component development and production planning at BCE.
A ceramic material that achieves the required properties in the laboratory is not yet a manufacturable component. Between material sample and reproducible production, geometry, process control and testing determine whether a research result becomes a reliable part.
BCE Special Ceramics contributes its practical manufacturing experience to research and development projects: from selecting and processing ceramic materials to manufacturing test parts and evaluating results under real production conditions.
We focus on three areas:
The following projects illustrate how BCE investigates new materials, design principles and manufacturing processes. They include completed research consortia as well as current development tasks whose technical feasibility is still being established.
PROJECT IN PREPARATION
Experimental development for pressure loads up to 3,000 bar
BCE is preparing the experimental development of a single-ended closed ceramic crucible designed to withstand pressure loads up to 3,000 bar. A potential application area is high-pressure NMR, where materials and components must function reliably under extreme pressure conditions.
The technical challenge lies in the interplay of ceramic material, component geometry and manufacturing process. In particular, the closed crucible base, the transitions to the wall and possible manufacturing-related defects influence the load-bearing capacity of the component.
The project aims to select suitable materials and geometries, manufacture test parts and evaluate them through pressure testing. The goal is to develop a reliable technical basis for ceramic high-pressure components where established materials or existing design solutions are insufficient.
An application for the German tax research incentive is planned for this project.
DURATION: 2021 TO 2024
Digital development of ATZ and ZTA ceramics
The InCoKer research project investigated how ceramic materials and their manufacturing processes can be developed and optimised more effectively using digital methods.
The focus was on ATZ and ZTA ceramics. BCE contributed its experience in the processing, manufacturing and practical evaluation of ceramic test parts.
The findings help to identify relationships between material composition, manufacturing process and subsequent component properties at an earlier stage.
DURATION: 2014 TO 2016
Ceramic joining solutions for extreme operating conditions
This research project addressed ceramic screw connections for applications where metallic fasteners reach their limits due to high temperatures, aggressive media or electrical requirements.
Conventional thread geometries cannot be transferred unchanged to brittle ceramic materials. A material-appropriate geometry was therefore developed and tested in practice.
The findings gained support BCE in evaluating ceramic fasteners and other components subject to high localised loads.
DURATION: 2009 TO 2012
Energy and resource efficient production of technical ceramics
The ENITEC joint project investigated how manufacturing processes for technical ceramics can be made more efficient and reliable.
BCE focused in particular on process simulation, dimensional accuracy and the question of how costly post-sintering machining can be reduced.
The findings gained support an early alignment of component geometry, material and manufacturing route.
Results from research projects cannot be transferred unchanged to every component. However, they broaden the technical basis on which BCE evaluates materials, geometries and manufacturing processes.
This is particularly valuable when:
BCE not only assesses whether a component can in principle be manufactured from technical ceramics. We also evaluate which material is suitable, what design modifications are necessary and which manufacturing route can be expected to produce a reliable result.
For an initial assessment, a drawing or sketch, information on loads and operating conditions and a description of the existing problem are helpful. We treat technical documents confidentially.
Does BCE participate in research projects?
BCE collaborates with companies, universities and research institutes on selected research and development projects. The focus is on ceramic materials, load-appropriate component geometries and new or improved manufacturing processes.
Does BCE also develop ceramic components for extreme pressure loads?
BCE is investigating a single-ended closed ceramic crucible for pressure loads up to 3,000 bar as part of a planned experimental development. The technical feasibility is to be assessed using suitable materials, adapted geometries, test parts and pressure tests.
Can companies approach BCE as a development partner?
Yes. BCE provides support in evaluating component ideas, selecting materials, manufacturing prototypes and developing suitable manufacturing processes.
Does BCE manufacture prototypes for development projects?
Yes. Custom ceramic components can be manufactured from a quantity of one. This allows materials, geometries and manufacturing routes to be evaluated using real components.
What information does BCE need for an initial assessment?
A drawing or sketch, information on mechanical load, pressure, operating temperature, chemical environment, required quantity and the material currently in use are helpful.
Are development enquiries treated confidentially?
Yes. BCE Special Ceramics treats technical documents and project information confidentially. If required, a confidentiality agreement can be concluded before any technical exchange.
We assess your requirements from the perspective of material, design and manufacturing. You receive a well-founded assessment of which next development steps are advisable.