Category: Applications & Solutions

The Manufacturing Challenge Overcome with Baikalox® SMA6?

Combining dissimilar materials inside dense ceramics has been a long-standing hurdle: conventional routes rarely deliver microstructural precision and preserved density. Additive manufacturing helped, but robocasting in air still constrains geometry and material pairings. The promising alternative—embedded 3D printing within a self-healing support—had proved difficult to translate to dense inorganic systems.

That changed when Imperial College London demonstrated an embedded route built on Baikowski’s SMA6.
In work titled Embedded 3D printing of microstructured multi-material composites and published in Matter (February 2024) , the team extruded complex architectures into a self-healing ceramic gel that yields to the nozzle and rapidly recovers, then—after controlled drying, debinding, and sintering—converts to dense alumina.

The result is defect-free, multi-material composites with sharp interfaces, opening design space for internal reinforcements and microchannels that conventional processing couldn’t reach.

Why SMA6 Alumina Made the Difference?

🌟 Ultra-Fine Particle Engineering

The choice of Baikalox® SMA6 with d₅₀ ≈ 0.2 µm proved decisive.
Its ultra-fine, tightly controlled particle-size distribution gives you the rheological “dials” you need—viscosity, yield stress, and recovery—so the nozzle passes cleanly and the matrix reliably self-heals.

The approach relies on gels with >25 vol% powder (matrix prepared at 7:3 wt/wt Al₂O₃:Pluronic), which supports dense sintering of both matrix and inks.

Packing is uniform enough to reach ~4–6% porosity after firing, and dispersion is controlled so interfaces remain sharp and porosity-free between embedded structures and the alumina matrix.

🌟 Processing Excellence

Before dispersion in Pluronic F127, SMA6 was sieved through a 100 µm plastic mesh to reduce agglomerates. With an appropriate dispersant (about 1 wt% relative to Al₂O₃), the powder forms a homogeneous, thermally reversible gel whose viscoelastic profile is well-matched to embedded printing.

How Does This Translate into Applications?

To validate the approach, the team demonstrated two use cases: co-sintered steel architectures that boost fracture energy without sacrificing strength, and sacrificial-graphite microchannels that deliver functional internal cooling in dense alumina.

🌟 1- Steel-Reinforced Alumina

SMA6 lets the steel architecture survive from printing to sintering, delivering real mechanical gains without giving up strength:

• Flexural strength: 155–289 MPa
• Fracture toughness: 3.3–4.0 MPa·m¹ᐟ²
• Work of fracture: up to 3.6 kJ/m² for auxetic lattices (≈ two orders of magnitude above unreinforced alumina, ~30 J/m²)

Why it works: auxetic frameworks steer cracks and spread plasticity in steel, boosting energy absorption while maintaining strength.

🌟 2- Advanced Thermal Management Systems

With sacrificial graphite printed inside the SMA6 matrix, you get dense alumina divided by clean, functional microchannels:

• Circular cross-sections approximately 200 μm diameter after sintering
• Wall thicknesses reduced to 50 μm between adjacent channels
• Proven cooling performance: temperature reduction from 119°C to 62°C in 200 seconds when flowing cold water through channels in a heated 2.6 × 2.6 × 1.5 cm³ alumina cube

These capabilities open new pathways for manufacturing thermal management systems with complex internal geometries previously impossible to produce.

How Did the Material Perform in the Study?

In short, the microstructure stayed tight and the printed features held their shape after firing. Overall density landed around 94–96% (≈ 4–6% porosity). Post-sinter, filaments remained in the ~70–260 µm range, and interfaces were sharp and porosity-free, as confirmed by SEM/EDX.

What Processing Parameters Were Reported?

Keep the window, and the parts keep their fidelity:

• Drying: 72 ± 3% RH, ~32 °C, ~2 weeks (on 16 × 16 × 16 mm cubes)
• Debinding: 1 °C·min⁻¹ → 350 °C (1 h); then 2 °C·min⁻¹ → 500 °C (2 h)
• Sintering: steel-reinforced parts to 1,450 °C (after a 600 °C step); microchannel parts to 1,550 °C

Which Conditions Make Embedded Printing Viable?

Five things have to line up—and SMA6’s PSD/dispersion helps tick each box:

• Viscoelastic match between ink and matrix
• Low matrix breaking stress so the nozzle can move freely
• Rapid matrix recovery so features don’t slump
• High ink yield stress to lock in filament geometry
• High inorganic content (matrix + inks) for dense, defect-free sintering

How Adaptable Is It Across Industries?

The method accommodates materials with very different properties within the Additive Manufacturinge SMA6 matrix, indicating broad adaptability across material systems.

Target Applications:

• Structural ceramics: aerospace, defense, automotive components requiring exceptional toughness without sacrificing strength
• Thermal management: electronics and energy systems with internal cooling channels
• Multi-functional devices: components combining structural and thermal functions
• Metamaterial-reinforced composites: architected structures with tailored responses

Why Partner with Baikowski?

Every Additive Manufacturing line has its own window. SMA6 excelled in this study, and Baikowski’s wider portfolio includes specialized alumina grades for diverse processes.

We help you tune powder, rheology and sintering: custom formulations that match your process parameters, collaborative optimization to boost yield and performance, consistent quality batch after batch.

Frequently Asked Questions

Can this process work with other alumina grades besides SMA6?
Yes—in principle for other ultra-fine grades—but each system needs its own rheology optimization. The key is a stable, high-solid gel with matched viscoelastic properties. Our team can help identify the optimal Baikowski grade for your application.

Why is particle size so critical for this application?
The 0.2 µm d₅₀ PSD enables precise rheological control near the gel transition, supports >25 vol% solids for dense sintering, and minimizes interfacial mixing—so boundaries between embedded structures and matrix remain sharp.

How does this compare to conventional ceramic composite manufacturing?
The auxetic steel-reinforced alumina achieved work of fracture values (3.6 kJ/m²) orders of magnitude higher than unreinforced alumina while maintaining comparable strength (155-289 MPa). This represents a significant breakthrough in overcoming the typical strength-toughness trade-off in ceramics.

What are the practical size limitations?
Feature size depends on nozzle diameter and matrix rheology. The study achieved filament diameters from 70-260 μm after sintering, with wall thicknesses between microchannels reduced to 50 μm. Finer features may be possible with smaller nozzles and optimized gel formulations.

Is the process ready for industrial production?
It’s repeatable at laboratory scale. Industrialization requires application-specific tuning of the powder–rheology–sintering trio, which our technical team can support.

Take the Next Step

Developing advanced ceramic composites or exploring novel AM approaches? Baikowski offers comprehensive alumina solutions backed by dedicated technical support.

💬 Connect with our Experts and download our 3D Printing White Paper — powder selection and process optimization for ceramic AM (including SMA6 insights)

In the quest for advanced optical components and durable catalyst supports, researchers have long faced the challenge of fabricating transparent spinel ceramics with high resolution and minimal defects.

A study tackled this challenge by testing a stereolithography (SLA) 3D printing method, complemented by a tailored hot isostatic pressing (HIP) process. At the heart of this study is the  Baikowski S30CR spinel, a high-purity material with an ultra-fine average particle size of approximately 50 nm and a specific surface area ranging from 25 to 28 m²/g that has enabled to produce complex-shaped transparent spinel ceramics.

Study Purpose: Overcoming Transparency and Resolution Challenges

The primary goal of researchers was to push the boundaries of 3D printed ceramics by achieving transparency and precision that rival conventional fabrication techniques, like die pressing and injection molding, while enabling intricately designed parts.
Furthermore, the study seeks to overcome the challenges posed by organic additives in many 3D printing processes, which often leave behind impurities and defects, thereby compromising the optical performance of the final product.

In summary, key challenges included:

• Achieving Near-Theoretical Transparency: Overcoming the inherent light scattering caused by residual pores and impurities.
• High Printing Resolution: Attaining fine details which are essential for creating intricate optical components.
• Uniform Densification: Ensuring a consistent and dense microstructure free of large pores that can hinder performance.

3D Printing: An innovative Process for Transparent Ceramic manufacturing

The unique properties of magnesium aluminate spinel enable materials that not only transmit light with near-perfect clarity but also withstand extreme environments. Spinel ceramics are in fact ideal for applications ranging from high-energy laser windows to catalytic supports in water treatment.

The Baikowski S30CR spinel exceptional characteristics enabled the refinement of 3D printing and subsequent heat-treatment processes, paving the way for the creation of spinel ceramics that exhibit remarkable transparency and intricate geometries with fine feature sizes. Notably, achieving full densification necessitated a HIPing temperature of 1800 °C, underscoring the high sintering activity of our spinel powder.

Here’s how the process unfolded:

• Preparation of the Printable Paste:
  The S30CR powder was meticulously dispersed in a photosensitive acrylate resin using an optimal concentration of dispersants. This created a ceramic paste with a uniform particle distribution and excellent self-holding ability, crucial for high-resolution SLA printing
  (​stereolithography).
• SLA 3D Printing:
  The prepared paste was used in a commercial SLA 3D printer. SLA additive manufacturing technique constructs objects layer by layer by directing a UV laser onto a vat of photosensitive resin, causing it to solidify into the desired shape. The method produced features as fine as 100–200 µm. Such precision is critical for applications in advanced optics where even minor deviations can lead to significant performance issues.
• Multi-Step Debinding and HIP Sintering:
  After printing, the green bodies underwent a carefully controlled multi-step debinding process to remove organic additives gradually. This was followed by a two-step sintering process: pre-sintering to boost the green body’s density, and HIP treatment to eliminate residual pores. This sequence was vital to obtaining a dense, almost pore-free microstructure.

Baikowski S30CR Outstanding Results

The printed spinel ceramics achieved a maximum transmittance of 84.8% at 1550 nm, reaching approximately 97% of the theoretical transmittance limit. Such transparency is a significant improvement over previously reported 3D printed ceramics and even exceeds many conventionally produced materials. These results are opening new avenues for advanced optical applications, including lenses, sensor windows, and artificial compound eyes used in robotics and surveillance.

The main results were:

Exceptional Optical Clarity:

The near-perfect optical performance is attributed to the uniform and dense microstructure enabled by the optimized processing techniques and the superior quality of the S30CR powder.

High Resolution and Design Flexibility:

The high resolution has been facilitated by the ultrafine particle size of Baikowski’s spinel powder, which is significantly smaller than the 355 nm wavelength of the UV light used in the SLA curing process. Consequently, UV light scattering is markedly reduced, leading to enhanced precision in the printed structures.

Robust Mechanical Properties:

The 3D printed ceramics boast a Vickers hardness of about 13.5 GPa, ensuring they can withstand harsh conditions where high temperature and chemical resistance are required.

Enhanced Thermal Stability:

Unlike common transparent polymers, these ceramics maintain their optical performance even when heated to temperatures between 800 and 1100 °C, making them suitable for applications in extreme environments.

To showcase the potential applications of these 3D-printed spinel ceramics, researchers have fabricated various transparent optical components, including lens arrays, Fresnel lenses, hemispherical domes, and microlattices such as Kelvin cells and simple cubic structures. Notably, the optical imaging performance of some components, like convex lens arrays, was evaluated, demonstrating their capability to produce clear and sharp images without distortion.

Furthermore, when utilized as supports for TiO₂ photocatalyst films, these transparent spinel ceramics significantly enhanced photocatalytic reactions compared to their opaque counterparts. This improvement is attributed to their larger illuminated surface area and controlled mass flow through intricately designed channels, highlighting their potential in environmental and energy applications.

This study marks a significant leap forward in the field of 3D printed transparent ceramics. Through a meticulously designed process combining SLA 3D printing with optimized debinding, sintering, and HIPing, researchers have achieved unprecedented transparency and precision in spinel ceramics. The use of Baikowski S30CR has been pivotal, proving that when innovation meets quality, the result is a material that not only meets but exceeds the demanding standards of modern engineering applications.

Read the full study titled 3D Printing of Transparent Spinel Ceramics with Transmittance Approaching the Theoretical Limit 

For those seeking a reliable solution to the challenges of 3D printed ceramics, the story of S30CR is a testament to the power of advanced material science. Explore our comprehensive 3D printing solutions white paper to discover how Baikowski is leading the way in delivering next-generation materials for tomorrow’s technological challenges.

High-purity sintered spinel materials have become increasingly valuable in a range of high-tech applications, thanks to their remarkable properties such as their durability, impact resistance, and optical clarity under extreme conditions, making them ideal for high-stakes environments

Produced with high-purity alumina and magnesium oxides, sintered spinel benefits from a continuous ceramic process that ensures a homogeneous product with uniform crystal sizes and low porosity.

The use of high-purity raw materials is essential for maximizing spinel high-temperature properties and minimizing impurities that could impact its performance. This underscores the need for rigorous production methods and stringent quality control measures.

High Purity Spinel Powders Optimized for Your Process

Our R&D teams have developed S15CR, S25CR, and S30CR spinel products that show controlled particle size and distribution, phase purity, and consistent crystallographic composition with low sulfur content and low metallic impurities, ensuring superior precision thanks to their:

• Superior Transparency: Low scattering loss ensures exceptional optical clarity, free from coloration or visible defects such as black or white spots.
• High Mechanical Strength: Exceptional durability for applications requiring resilience under demanding conditions.
• Customizable Chemistry: Tailored compositions, including Co, Mn, Fe doping, and adjustable Al/Mg stoichiometry, to suit diverse applications.

Baikowski® uses advanced analytical techniques to monitor and maintain these critical parameters, ensuring that every product meets the highest industry standards.

For streamlined processing and consistent results, all our powders are also available in spray-dried and ready-to-press forms.

Moreover, the latest addition to our range, S15CR, features a lower specific surface area and larger grain size, making it particularly suited for tape casting and feedstock applications, where precision and scalability are crucial.

Learn more about our spinel offering

Growing Demand for High-Purity Spinel Powders

🌟 In the Photonics, Electronics, Aerospace industries…

Spinel is playing a transformative role in several emerging technologies and industrial sectors requiring superior optical and mechanical performance such as in:

• Photonics: spinel transparency across a broad wavelength range makes it a prime candidate for use in optical windows, lenses, and high-performance coatings. Its low scattering loss and exceptional purity also make it a preferred material in advanced displays, laser systems, as well as in inorganic detection systems, where optical clarity and precise signal transmission are critical for accurate results.
• Electronics: In the semiconductor industry, spinel excellent thermal stability and resistance to wear make it an excellent substrate material for thin-film deposition and other electronic applications.
• Aerospace: Thanks to their ability to withstand extreme conditions and provide optical clarity, spinel is widely used in spacecraft and satellite components.
• Environmental applications: Spinel powders are increasingly utilized as catalysts in chemical processes due to their high surface area and stability under harsh conditions. Applications range from energy conversion systems to environmental remediation technologies, where the ability of spinel to enhance reaction efficiency and longevity makes it a valuable material. For instance, in pollution control, spinel-based catalysts help reduce harmful emissions by promoting the efficient breakdown of pollutants
• Watchmaking: for scratch-resistant watch faces, and durable lenses.

All these application fields highlight spinel versatility across both technical and consumer markets. Additionally, the 3D printing process now allows for increased design flexibility. Learn more in this article: Superior 3D Printed Transparent Spinel Ceramics with S30CR, a summary of a study titled 3D Printing of Transparent Spinel Ceramics with Transmittance Approaching the Theoretical Limit.

🌟 Advancements in Spinel Materials: Expanding Applications

One of the most exciting recent developments in spinel technology is the advent of ultra-wide-band-gap spinels, such as zinc gallate (ZnGa₂O₄). These materials are paving the way for next-generation semiconductors, offering superior energy efficiency and thermal stability.

In addition, advancements in spinel ferrite nanoparticles have expanded their applications in biomedical imaging, drug delivery, and magnetic data storage. These innovations demonstrate the immense potential of spinel materials in shaping the future of high-tech industries.

In conclusion, the unique properties of high-purity sintered spinel have made it indispensable in cutting-edge applications such as photonics, semiconductors, environmental technologies and even in advanced filtration systems, including water filtration.

As the demand for  transparent spinel ceramics grows, our expertise in customizing spinel powders with tailored chemical compositions and precise particle size control, supported by robust R&D and advanced analytical capabilities, ensure efficient solutions.
Contact us to discuss your specific needs.

Why could Matrix Doping be the Key to Thermal Stability in Oxide CMCs?

Across the aerospace and energy industries worldwide, oxide Ceramic Matrix Composites (Ox-CMCs) play a key role in demanding applications such as gas turbine engines, aerospace thermal protection systems, and energy generation components.

Their outstanding mechanical strength, thermal stability, and chemical resistance make them essential in environments where other materials fail. However, ensuring long-term stability above 1000 °C remains a challenge, mainly due to grain coarsening and material degradation.

Advanced Research: Matrix Doping for Thermal Stability

A recent study, University of Bremen study on Ox-CMCs, investigated ways to preserve microstructure and strength at high temperatures.

Baikowski® contributed to this research with its Baikalox® BA15 alumina powder, selected for its:
• Ultra-high purity
• Narrow particle size distribution (d₅₀ = 120 nm)

These attributes ensured a consistent and reliable matrix material, critical for evaluating the effects of doping. For that, water-based ceramic suspensions containing a solid content of 50 vol% were prepared.

Materials and Methods Overview

• Reinforcement: Composites reinforced with Nextel™ 610 fibers and alumina matrices
• Matrix Variations: Non-doped alumina vs. MgO-doped alumina (480 ppm). MgO was chosen due to its recognized ability to inhibit grain boundary mobility and reduce grain growth, making it an effective doping agent for enhancing thermal stability.
• Processing Route: Ionotropic gelation, sintered at 1200°C, then heat-treated at 1300°C and 1400°C
• Characterization: SEM, WDX, and tensile strength testing

Key Results: The Baikowski® Advantage

🌟 Microstructural Improvements

• Both composites started with uniform, equiaxial grains
• After heat exposure, MgO-doped composites showed refined grains and fewer abnormal grain formations, especially near fiber regions

🌟 Elemental Interactions

• WDX analysis showed that silicon (Si), which is part of the Nextel 610 fibers, diffuses outward toward the matrix after heat exposure
• Magnesium (Mg) from the matrix diffuses slightly into the fibers. This interaction helped suppress excessive grain coarsening in MgO-doped composites, leading to narrower fiber grain size distributions and smaller grains compared to non-doped samples
• Result: reduced strength loss after heat treatments

🌟 Mechanical Performance

• Initial tensile strength: ~135 MPa for both doped and non-doped composites
• Post-treatment strength retention:
– 1300 °C: MgO-doped → 8% loss (vs. 27% for non-doped)
– 1400 °C: MgO-doped → 41% loss (vs. 62% for non-doped)

👉 The customized doped alumina matrix significantly limited fiber grain growth and maintained mechanical properties under high-temperature exposure.

Why Baikowski®?

With more than 100 years of expertise and strong R&D capabilities, Baikowski® delivers tailored high-purity oxides for critical applications such as aerospace and energy.

Our ability to engineer customized alumina powders and slurries ensures optimal performance in your most demanding processes across EMEA, the Americas, and APAC.

Explore our CMC solutions portfolio, including:

• Baikalox® BA15 powder → High-purity alumina for matrix formulations
• SLAZ slurry → Alumina doped with Mathym’s zilight® nano-zirconia for advanced thermal protection

👉 Eager to learn more about Advanced Materials for oxide CMCs 

 

With over 120 years of expertise, Baikowski® is a leading provider of advanced materials. We began by offering synthetic sapphire and then later expanded to powder solutions, including polishing solutions for the watchmaking, optics, electronics and semiconductor industries.

With our engineering and experience we are able to deliver customized alumina and colloidal silica solutions with optimized morphology, particle size distribution (PSD), and chemistry for applications requiring a superb finish produced with high efficiency.

In electronics and optics, where polished sapphire is crucial for high-performance devices, Baikowski’s® slurries help achieve surfaces free of micro-defects that can adversely impact light transmission and image clarity.

Sapphire Polishing Challenges

Polishing sapphire, one of the hardest materials known after diamond, demands meticulous, high-precision processing to achieve flawless, defect-free surfaces.

The primary challenges include surface defects, micro-scratches, and incomplete removal of grinding marks, all of which affect optical clarity and the final surface finish.

Achieving the perfect polish involves mastering three stages: rough grinding to remove initial material, intermediate polishing to refine surface irregularities, and final polishing for a mirror-like surface. Each step requires precise control to avoid introducing new imperfections.

C-axis & A-axis: The Impact of Crystal Orientation

The crystal orientation of sapphire is significantly related to polishing difficulty. The C-axis (0001 plane) is the hardest orientation to polish, presenting up to 20% more resistance, and requiring specially formulated slurries to achieve a fine, imperfection-free finish.

In contrast, the A-axis (11-20 plane) can be easier to polish but it still demands rigorous control. Slurries must be engineered to offer the proper abrasive particle size distribution, and pH to accommodate hardness variations and achieve uniform results across these orientations.

 

SPH Silica & Alumina-based Slurries for Enhanced Sapphire Polishing Productivity

Baikowski® has developed a unique CMP series in which chemicals play a major role to deliver smoother finishes with higher levels of precision on such hard substrates. This SPH specific range of patented alumina and silica-based slurries is tailored to improve productivity, especially on sensitive crystal planes such as that of the sapphire C-axis.

This range achieves remarkable efficiency, delivering 3 to 4 times faster material removal rates compared to traditional colloidal silica slurries. In addition, it achieves consistent material removal due to:

• The Controlled Morphology and Narrow PSD of Baikowski® milling optimized sapphire polishing slurries. They minimize the risk of introducing new scratches while balancing efficient material removal, making the series particularly effective in intermediate and final polishing.
• The stability of the suspension. It ensures uniform material removal and sustains good particle dispersion throughout the polishing process. The carefully balanced viscosity and pH enhance the slurry’s chemical activity on sapphire surfaces, accelerating the polishing process and making the SPH series ideal for applications where ease of use and high precision are priorities.

Baikowski’s® SPH series are available in both Silica and Alumina abrasive solutions

• SPH-51 is a silica solution, with specifications for D50 of 100 nm, and a pH of 10-11. It delivers high removal rates on sapphire’s C and A planes, achieving near-perfect surface finishes, especially when combined with Baikowski® polyurethane pad.

Performance of sph-51 Silica solution (A plane)
Polishing Conditions

Machine	φ 610 mm single side
Plate rotation (rpm)	50
Down force (g/cm²)	280
Slurry flow(ml/min)	100
Work	Sapphire A plane

 

This results in an ideal surface, ready for epitaxial layers, to ensure optimal light output and energy efficiency in the final LED application as one example.

• SPH-53 is also an optimized silica-based solution that provide an intermediate removal rate with proven performance over that of traditional silica. The specifications for D50 is 70 nm and it has a pH of 8-9.

Comparison of SPH-51 & SPH-53 Silica solutions (C PLANE 4’’)
Same polishing conditions as describe above

Products	Traditional Silica	SPH-51	SPH-53
Temperature (°C)	36	47	35
Torque (%)	100	139	94

 

• The SPH-9D slurry is a very high removal rate alumina product, ideal for C-axis. It effectively removes surface irregularities and produces a best in class surface
  The specifications for D50 is 0.30 µm and it has a pH of 12.5–13.5. This slurry can also be utilized in dual face polishing operations.

ALUMINA-BASED SLURRIES COMPARISON
Surface Roughness 0.2 nm – 0.35 nm

 

Achieving optimal polishing results require the right combination of polishing speed, pressure, pad quality, and slurry formulation. Higher polishing pressures increase material removal rates but may induce scratches, while slower speeds often reduce scratch formation but can extend process time.

Learn more about SPH products

 

In summary, our SPH silica and alumina-based slurries offer a superior alternative by providing faster removal rates, reduced incidence of defects, improved surface finish, and enhanced process control over traditional silica products. The range, combined with the proper pads is ideal for high-precision applications in the optics, electronics, and semiconductor industries where surface quality and productivity are both critical.

Eager to learn more about Baikowski®’s polishing solution offering ?
Explore our dedicated White Paper titled Superior Intermediate & Final Polishing, Alumina, Silica, Ceria  & Diamond Solutions

This article summarizes the study “Transparent Alumina Ceramics Fabricated by 3D Printing and Vacuum Sintering”, which explored the potential of additive manufacturing to revolutionize ceramic fabrication.

The research demonstrated that combining 3D printing with high-performance materials like Baikalox® CR10 alumina powder, enhanced with MgO doping, could rival traditional manufacturing methods in terms of quality while introducing unprecedented design flexibility.

Since the study’s completion in 2020, advancements in 3D printing technology have continued to push boundaries, offering even greater precision, scalability, and potential applications.

The Goal: Pioneering 3D Printing for Transparent Ceramics

Transparent ceramics have long been valued for their exceptional mechanical, thermal, and optical properties, with applications spanning aerospace, defense, optics, and electronics. However, traditional fabrication methods, such as cold isostatic pressing (CIP) and vacuum sintering, often require extensive tooling and are limited in producing complex geometries.

This study aimed at addressing these limitations by leveraging extrusion-based 3D printing to fabricate high-density transparent ceramics, exploring the use of two-step vacuum sintering to optimize optical and mechanical performance.

The goal was to evaluate whether 3D printing could deliver results comparable to CIP while enabling greater design flexibility.

The Process: From Powder to Transparency

The fabrication process involved several key steps, each optimized to achieve near-perfect transparency in the final ceramics.

Baikowski Powder Properties

Baikalox® CR10D alumina powder, enhanced with 625 ppm MgO doping, a composition specifically tailored for superior sintering performance, was used in this study. This high-purity alumina features a controlled submicron particle size (D50: 0.731 µm) and a narrow particle size distribution, making it ideal for achieving high-density ceramics. The addition of MgO acted as a sintering aid, effectively promoting densification and enhancing grain boundary control during the vacuum sintering process.

The specific surface area (SSA) of the powder, measured using the BET method, was 7.9571 ± 0.1174 m²/g.Its submicron size, high surface area, and nearly spherical morphology ensure excellent packing efficiency and optimal densification behavior, critical factors for producing transparent ceramics with superior optical and mechanical properties.

Learn more about Baikalox® CR range

Slurry Formulation

To prepare the ceramic slurry for 3D printing, Baikalox® CR10D powder was combined with water and a small percentage of ISOBAM™, which served as both a binder and dispersant to achieve the desired viscosity.The optimal formulation—72 wt% alumina and 0.7 wt% ISOBAM™—struck the perfect balance between viscosity and printability.

This carefully optimized slurry exhibited shear-thinning behavior, allowing for smooth and precise extrusion through the printer nozzle while ensuring structural stability during and after printing.

3D Printing Technology and Post-Processing

The slurry was loaded into an extrusion-based 3D printer, allowing the creation of complex shapes layer by layer. The printed parts were then dried, debinded, and sintered using a two-step vacuum sintering process. This approach minimized grain growth while achieving near full density (>99%).

Final polishing enhanced the transparency, resulting in ceramics with a total transmittance of up to 70% at 800 nm.

Key Insights and Applications of 3D-Printed Ceramics with Baikalox® Alumina

Several benefits in terms of capabilities of 3D printing for transparent ceramics were revealed by the study:

• Performance Equivalence
  The study demonstrated that 3D-printed ceramics using Baikowski®’s CR10D alumina powder achieved over 99% relative density and similar transmittance levels (70% at 800 nm) to CIP-processed ceramics, reinforcing the reliability of additive manufacturing for optical-quality applications.
• Innovation in Geometry
  Unlike usual methods, 3D printing allowed for the creation of complex shapes without compromising quality, showcasing its advantage for customized and intricate designs.
• Optimized Processes
  Two-step vacuum sintering enhanced transparency by reducing grain size compared to single-step sintering, underscoring the benefits of process optimization.
• Technology Evolution
  While this study represents the state of technology in 2020, 3D printing has since improved in resolution, materials, and scalability, further expanding its potential for intricate geometries in high-performance applications.

For additional details, explore the full study here

These results could have implications for various industries. Transparent ceramics are critical in optical lenses, protective windows, and laser systems. The design of custom geometries enables the creation of advanced optical components, improving performance and reducing manufacturing costs.

As technology continues to evolve, its potential for intricate geometries and miniaturized components expands the horizon for applications in photonics, sensors and more.

This study reinforces Baikowski®’s commitment to driving innovation through high-quality materials. The use of Baikalox® CR10D powder highlights the critical role of advanced materials in enabling the success of such cutting-edge technologies.

Learn more with our white paper dedicated to Ceramic 3D printing powders and slurries.

 

Ceramic Matrix Composites (CMCs) represent a transformative breakthrough in materials science, addressing the growing demand for high-performance materials in extreme environments. These composites retain the thermal stability, corrosion resistance, and mechanical strength of ceramics while overcoming their inherent brittleness through composite engineering.

CMCs are increasingly utilized in aerospace, energy, medicine, and electronics, where lightweight structures, high-temperature resistance, and mechanical durability are essential.

To fully unlock their potential, precise control over the matrix composition is crucial. In fact, the matrix must ensure:

✔ Excellent dispersion of ceramic particles in the slurry
✔ High solid loading with low viscosity for better infiltration
✔ Compatibility with additives to tailor performance
✔ High reactivity for efficient consolidation
✔ Controlled porosity to enhance mechanical properties

1. Ox/Ox CMCs: Performance and Challenges

Ox/Ox CMCs are typically composed of alumina or mullite fibers embedded in an oxide matrix. These fibers enhance strength, toughness, and thermal resistance, while the matrix plays a key role in load transfer, fiber protection, and crack deflection. Studies show that an optimal matrix porosity of around 30% is ideal for balancing mechanical strength and thermal performance.

Several challenges must be addressed to achieve such Ox/Ox CMC performance, including:

✔ Mechanical Degradation of Ceramic Fibers at High Temperatures
✔ Grain Growth Leading to Reduced Mechanical Strength
✔ The Need for Low-Temperature Sintering to Preserve Fiber Integrity

However, achieving this requires precise control over particle size distribution, doping levels, and viscosity. This is where Baikowski®’s SLAz slurry comes into play, offering an advanced high-purity alumina and nano-zirconia solution that meets these critical parameters.

2. SLAz: The Key to Next-Generation Ceramic Matrix Composites

SLAz is Baikowski®’s high-purity α-alumina slurry, enhanced with a customized ratio of zilight® nano-zirconia—the smallest nano-zirconia on the market—developed by Mathym®, a Baikowski® Group company. The SLAz range includes a doping level of nano zirconia up to 28 wt%, a solid loading of slurries up to 60 wt%, low viscosity, and a large pH range, that enable:

1- Controlled Grain Growth & Microstructure Stability
Mathym’s nano-zirconia effectively limits excessive alumina grain growth, helping to preserve the mechanical integrity of the matrix. Additionally, its uniform dispersion ensures consistent microstructural performance throughout the composite, leading to enhanced reliability and durability.

2- Enhanced Processability & Stability
SLAz remains stable across a wide pH range (4–10), ensuring long-term slurry stability during processing and optimizing manufacturability. SLAz‘s responsiveness to sintering allows it to consolidate at low temperatures, preserving fiber integrity.

3- Enhanced Fiber Protection & Mechanical Properties
SLAz could reinforces the alumina matrix, making it an ideal solution for high-performance applications in extreme environments.

3. SLAz Slurry Characterization

Baikowski® has rigorously engineered SLAz to meet high-performance standards such as:

✔ Low Viscosity – Ensures easy processing and fiber infiltration.
✔ Zeta Potential Optimization – Provides a stable suspension with a wide pH range.
✔ Controlled Doping Levels – Up to 28% nano-zirconia, ensuring fine microstructure control.
✔ Tailored Solid Loading – Up to 60 wt% for high-density matrix formation.
✔ Homogeneous Dispersion – Guarantees uniform properties after sintering.

Viscosity

 

• Viscosity remains low (below 0.3 Pa.s)

 

 

 

 

Zeta potential curves

Zeta potential curves of SLAz and pure zilight® dispersion are similar:

• High SSA
• Higher dispersant amount in zilight® dispersion
• zilight® tends to form a layer on alumina grain surface

3. Ceramics characterization SLAz

Densification occurs at higher temperature with zilight® doping and Homogeneous dispersion limits grain growth.

For more information on Baikowski’s CMC solutions, download our leaflet and do not hesitate to contact our team.

 

 

If Baikowski® continues to innovate for high-performance Ox/Ox CMC, our R&D team do not stop there.

Recognizing the growing demand for mullite-based CMCs, Baikowski® has also developed SLMz, a tailor-made mullite slurry doped with zilight® nano-zirconia.
Early results show promising effects similar to SLAz, including a comparable impact on zeta potential, an IEP downshift dependent on zilight® loading, and a significant decrease in viscosity.

Our expertise in producing small-sized particles, controlling morphology, optimizing particle size and distribution, and offering various doping options positions us as a partner of choice in advanced material solutions for medical applications.

1-    Biomaterials: Zirconia Composite Powders and Slurries

Tailored ZTA Solutions for Bioceramics and Cutting Tools

Baikowski®’s ZTA products, which combine tailored alumina and zirconia, exhibits high chemical purity, homogeneous particle distribution, and fine microstructures, to meet the stringent demands of medical applications such as prostheses or implants.

Our customization know how allows us to optimize composition to enhance mechanical properties for medical needs like superior resistance to shocks and wear. It is the case of scalpels and cutting tools inserts that require sharpness and strength to make precise incisions with minimal wear over time.

 

Available in forms such as spray-dried powders and slurries, our ZTA products integrate seamlessly into various manufacturing processes.

Learn more about our ZTA 

Moreover, our commitment to quality is underscored by our ISO 22000 certification for food safety, ensuring our products meet stringent European pharmacopeia standards, and ISO 14001 certification for environmental management.

Nanozirconia with High Refractive Index for Dental and Optical Applications

In dental applications, zilight®, with its nano-zirconia particles as small as 5nm, is an ideal choice for dental prosthetics, ensuring durability, aesthetic appeal, and long-term health benefits. Nano-zirconia is biocompatible, brings also radiopacity and thanks to its small size can yield to translucent materials.

Additionally, filyxio® YbF₃ nanofillers, provides high radiopacity and stronger mechanical properties, but also improved color stability and translucency. filyxio® is the smallest filler on the market, making it ideal for achieving high depths of cure in dental composites.

Learn more about Mathym’s unique dental restorative solutions in our dedicated White Paper Titled:
Nanofiller Dispersions for Superior Dentistry Restorations  

In optical applications, zilight® provides customizable refractive index, essential for ophthalmic coatings and displays, without compromising transparency and haze. This results in high-performance optical materials with enhanced scratch and wear resistance.

Download our optical & ophthalmic coatings White Paper

2-   Gamma-Alumina for Purification & Dermatological Applications

Baikalox® gamma-alumina powders, such as BA100 and BA105, are used as purification agents during the manufacturing of advanced cosmetic and medical ingredients. They facilitate the removal of metallic and ionic impurities to achieve high-purity compounds suitable for sensitive formulations. For example, this purification process can be applied during the production of hyaluronic acid (HA) used in medical and some high-end cosmetic applications.

In addition, Baikalox high-purity alumina powders, such as CR15, are employed in microdermabrasion procedures and dermatological formulations, where their controlled particle size and morphology enable effective yet gentle exfoliation, suitable for both aesthetic treatments and clinical dermatology.

3-    Alumina, ceria and silica for Finishing Polishing

As a leading fine minerals manufacturer, Baikowski® is also committed to finishing polishing of surgical instruments, diagnostic tools, optical components, implants and beyond.

For that purpose, we design custom abrasives powders and slurries such as high-purity alumina, ceria, and silica. Regarding alumina for instance, we can play on the size of the particles and the particle size distribution in order to fit the most closely with the required surface finish, but also tailor the alpha alumina rate into a gamma alumina matrix.

Alumina solutions for Metal Finishing Polishing

High-purity alumina offers exceptional hardness and abrasive qualities necessary for achieving smooth and precise finishes on surgical tools and implants. A polished surface reduces the risk of tissue irritation and promotes better integration with body tissues.

Baikowski®’s alumina powders and slurries are engineered for optimal particle size and purity, ensuring that the polishing process minimizes surface roughness while maintaining the integrity and sharpness of metal instruments.

Learn more about how our fine alumina with high specific area outperforms traditional silica solutions, offering both higher performance and greater ease of use in metal polishing and metallograpgy in our dedicated article.

High Puriy Alumina for Optical kiss- Polishing

High-purity alumina is essential for polishing optical components used in diagnostic tools such as endoscopes and microscopes for instance, as well as for lenses, mirrors and prisms.

The exceptional purity of Baikowski®’s alumina ensures that no impurities compromise the optical clarity of these components. As to the controlled particle size distribution of our solutions, a flawless finish that enhance light transmission and image clarity can be achieved.

Explore some of our alumina polishing solutions

Ceria and Silica-Based Polishing Solutions in the medical field

Cerium Oxide (CeO2):

Cerium oxide is commonly used for polishing delicate surfaces like those found in ophthalmic implants or microfluidic devices. Its mild abrasive properties make it suitable too for softer materials, such as certain plastics used in medical devices. For more information on tailored ceria solutions for medical applications, please contact us.

Silica (SiO2):

Silica, particularly in the form of colloidal silica, is a very fine polishing material used for achieving high surface finishes with minimal defect formation. It is ideal for polishing delicate surfaces or materials prone to scratching. However, for a high degree of surface smoothness, especially on harder substrates such as stainless steel, titanium and ceramics, alumina is generally preferred.

To find the ideal abrasive solutions for your substrates, delve into our product selection guide within our Polishing Solutions White Paper and do not hesitate to contact our experts for guidance.

In fact, Baikowski® Group have a strong expertise based on alumina, silica, ceria abrasive grains and chemical agents, especially when precision and/or selectivity in material removal are demanding.

 

 

Download our Polishing Solutions White Paper

 

 

 

Baikowski® alumina powders are designed for use in abrasive preparations for the maintenance of vehicles, specifically for the polishing of varnish, lacquer, and painted surfaces during automotive detailing, surface correction, and finishing operations. Our tailored grades, such as GE30, BA20, AD15, PB20CR, and PB50CR, offer optimal cutting efficiency, controlled deagglomeration behavior, and superior surface gloss for intermediate and superfinish polishing stages.

In automotive manufacturing, advanced polishing materials that deliver both precision and an impeccable finish are essential. At Baikowski®, we specialize in producing custom fine alumina powders that not only meet the highest standards but also provide a competitive edge by reducing polishing time and achieving a superior high-gloss finish. This is crucial in the intermediate and superfinish polishing stages, where balancing cutting efficiency with an outstanding gloss and transparency is key.

Intermediate Polishing: Accelerating the Polishing Process to Perfection

The intermediate polishing stage focuses on efficiently removing imperfections such as swirl marks, fine scratches, and oxidation. Baikowski® alumina powders are engineered to eliminate these defects quickly while minimizing surface abrasion, reducing polishing time and ensuring a smooth transition to the superfinish stage.

Superfinish: Achieving a Mirror-Like Shine Without Micro-Scratches

At the superfinish stage, the goal is to achieve a deep, reflective gloss that enhances the quality of the vehicle’s paintwork. Baikowski® alumina powders, with their controlled SSA and morphology, provide the fine abrasiveness needed to attain this result without introducing new imperfections.

Baikowski®’s Tailored Car Polish Solutions

Our fine alumina powders are engineered with a strict focus on quality and performance. The following properties are meticulously controlled to ensure optimal results in intermediate and superfinish polishing:

• Specific Surface Area (SSA): Our powders are formulated with optimized SSA values to achieve the right balance between cutting action and surface gloss. A lower SSA promotes aggressive cutting, while a higher SSA indicates finer particles essential for the superfinish stage, where a smooth, reflective surface is required.
• Morphology: We tailor the particle shape to optimize polishing efficiency. Sharp particles enhance cutting ability, while more rounded particles reduce the risk of micro-scratches, ensuring a flawless, high-gloss finish.
• Crystallinity: Our alumina powders feature the ideal crystallinity for consistent cutting performance. This ensures long-lasting effectiveness throughout the polishing process, reducing time spent while maintaining a high-quality finish.
• Particle Size Distribution (PSD): Controlling the PSD ensures consistent particle behavior throughout the process to prevent surface damage and achieve a good balance between removing imperfections and preserving the underlying surface quality.
• Deagglomeration Ability: Our powders are designed to ensure alumina particles remain well-dispersed in the polishing slurry. Theses slurries consist of agglomerates of fine particles specifically engineered to break down during the polishing process. The controlled deagglomeration enables an initial strong cutting action that gradually transitions to a finer, softer polishing effect, leading to a mirror-like finish. This dynamic behavior contributes to both time-efficient processing and exceptional surface quality.

Choosing the right alumina powder with the optimal combination of SSA, morphology, crystallinity, PSD, and deagglomeration ability enables professionals to achieve the expected results.

Our proven products, such as GE30, GE15,BA20, PB20CR, and PB50CR, deliver unmatched performance in car polishing, shortening the process while achieving a brilliant finish. However, realizing their full potential requires the right combination of alumina solution and polishing pad. Ready-to-use products, such as GE15S slurry, are also available.

As demand for advanced varnish and lacquer polishing solutions continues to rise, Baikowski® remains a leader in the industry by providing custom alumina powders that meet the specific needs and process of our clients.

 

Additionally, we continue to develop new powders dedicated to varnish and lacquer applications, aimed at simplifying and accelerating the car polishing process.

See some of our polishing solutions

As the global demand for effective water treatment systems grows, particularly in regions where access to clean drinking water is scarce, the development of innovative filtration technologies has become a focus.

In a recent study titled “Removal of MS2 and fr Bacteriophages Using MgAl₂O₄-Modified, Al₂O₃-Stabilized Porous Ceramic Granules for Drinking Water Treatment”, researchers investigated the effectiveness of an advanced composite-based filtration membrane.

This ceramic membrane, made from alumina (Al₂O₃) and Baikowski® magnesium aluminate spinel (MgAl₂O₄), demonstrates potential for removing viruses, such as bacteriophages and other microorganisms that contribute to waterborne diseases.

Combatting Waterbone Pathogens with Spinel-based Composite Membranes

The membrane is fabricated by integrating spinel granules into an alumina matrix. This composite approach leverages the mechanical strength of alumina, and the filtration capabilities of spinel due to its fine pore structure and stability.

The Baikowski® product used S25CR is a high-purity jet-milled spinel powder (dv50 = 0.25 µm and surface area of 21–24 m²/g).

This combination of materials allows the membrane to maintain its performance even in extreme environmental conditions.

Baikowski® Spinel Powder Benefits for advanced filtration applications

At Baikowski®, spinel powders are designed to achieve the highest standards in ceramic applications. Here’s how our S25CR product align with the demand of advanced filtration systems:

• Particle Size and size distribution: Our jet-milled spinel powder offer fine particle size and controlled particle size distribution around 0.25 µm that enable precise tailoring of membrane porosity.
• High Purity Levels: With over 99% phase purity, our spinel powder minimizes impurities that can interfere with membrane performance. This purity is essential in preventing contamination, which can degrade the efficacy of filtration in sensitive applications like water filtration.

Post-Filtration Characterization and Thermal Regeneration

A critical part of the study involved characterizing the materials after filtration to assess the durability and stability of the membrane. X-ray diffraction analysis confirmed that the phase composition of the spinel granules was preserved after exposure to 2 liters of contaminated water, indicating the membrane’s robustness. Electron microscopy further demonstrated that the granular structure remained intact, ensuring the membrane’s continued effectiveness even after prolonged use.

Additionally, the study measured the release of aluminum and magnesium into the permeate after filtration. No aluminum was detected, and the magnesium levels were significantly below the WHO’s recommended threshold for drinking water. This low level of magnesium release is a notable benefit, as excessive magnesium in water contributes to hardness.

One of the standout features of the spinel-based filtration system is its potential for thermal regeneration. When the membrane’s pores become clogged with contaminants, heat treatment at 400°C can restore its filtration capacity. This ability to regenerate the membrane extends its lifespan and makes it a more sustainable solution for water treatment.

Product Customization

In conclusion, spinel-based composite membranes offer a solution for filtering viruses and other microorganisms from drinking water, with the added benefit of being durable and regenerable. The Baikowski®’s high-purity spinel powder, S25CR, play a role in these advanced filtration technologies, ensuring both high filtration efficiency and long-term stability.
For more detailed insights, you can explore the full study here.

At Baikowski®, our R&D teams customize solutions, such as adjusting the dopant or the particle size, to meet your specifications. We work closely together to develop products that push the boundaries of your application needs. Any questions? Contact-us

The search for dental restorative materials that seamlessly blend strength, safety, and aesthetic appeal has long been a priority in dentistry. Mathym®’s innovative nano-zirconia suspension with high refractive index, zilight®, is at the forefront of addressing this challenge.

Meeting the Demand for Aesthetic and Strong Dental Materials

Patients are looking for dental restorations that are not only durable but also visually natural. Traditional materials like porcelain-fused-to-metal often fall short, especially in visible areas like the front teeth due to their opacity and sometimes greyish hue. While all-ceramic restorations offer some improvements, they still face some issues such as chipping, brittleness, and in particular limited translucency.

Yttria-Stabilized Zirconia (YSZ) ceramics, particularly those doped with 3 mol.% yttria (3YSZ), have gained popularity for their high strength, biocompatibility, and compatibility with CAD-CAM technologies. However, conventional 3YSZ often lacks the translucency required for highly aesthetic dental restorations.

Achieving Superior Optical and Mechanical Properties with zilight® range

The control of Mathym’s zirconia grain size to less than 100 nm enables to produce high translucency ceramics without compromising solidity. Moreover, the adjustment of yttria doping in the 8 mol.% range also allows enhanced optical transparency. The obtained ceramics exhibit opalescence similar to natural enamel, creating a bluish and orange appearance under different lighting conditions.

These properties linked to the miniaturization of residual pores, the refinement of grain size, proper doping concentration, and sintering ability at only 900°C make zilight® a superior alternative to existing commercial options for dental applications.

The low sintering temperature is a remarkable competitive benefit that also allows energy consumption reduction, short processing times, and can minimize potential thermal damage to other components.

Compatible with ceramic 3D printing, our innovative solution is designed to meet advanced restoration techniques needs.

Enhancing Dental Applications with Mathym’s Innovations

Mathym’s commitment to innovation extends beyond zilight® nano-zirconia suspension.

Our offering also includes our well-known filyxio® nanofillers, our advanced nano ytterbium, as well as our nano cerium fluorides, designed to enhance or add specific properties to dental materials such as radiopacity, wear resistance and color stability.

Aditionally, the nanoparticle functionalization ensures compatibility with various dental monomers, even at high concentrations.

All these advancements bring superior results across a variety of restorative procedures while preventing secondary caries by inhibiting bacterial growth and promoting enamel remineralization.

For further details and tailored solutions, contact our teams to discuss your needs and download our white paper !

Unveiling the microstructure of metals requires meticulous surface preparation. Metallographic polishing, employed in fields like materials science and engineering, achieves this by creating a flawless, scratch-free surface for microscopic analysis.

Traditionally, various abrasive materials and polishing techniques have been employed such as Colloidal silica for its dispersion ability.
Nowadays, alumina materials are prefered for polishing soft metals, offering enhanced results and processability.

The Superior performance of Baikalox® Alumina for Aluminum and Copper Alloys

The results here are based on the comparative performance of our Baikalox® fine alumina versus traditional colloidal silica in finishing polishing of aluminum alloys and copper samples.

Our fine alumina polishing solutions offer a compelling alternative in terms of :

1. Surface Finish Quality

High-resolution SEM images allowed for detailed observation of surface topography, revealing the absence of scratches, pits, and orange peel effects with Baikalox® polishing.

• Scratch-free: The uniform particle size and high specific surface area of the Baikalox® solutions contributed to a better consistent and controlled material removal than colloidal silica, preserving the integrity of the microstructure for accurate analysis.
• Orange Peel Effect-free: This is a common challenge encountered with colloidal silica, where uneven polishing creates a wavy surface reminiscent of an orange peel. Baikalox®, with its higher polishing efficiency offered a superior flatness and surface finish

2. Time Reduction

The use of fine alumina significantly reduced the overall polishing time thanks to its enhanced abrasive action, which facilitates faster material removal without compromising surface quality.

3. Ease of Cleaning

Colloidal silica suspensions can be challenging to clean.  On the contrary, the alumina particles were less prone to embedding in the sample surface, reducing the need for extensive cleaning procedures, promoting faster sample turnaround times and minimizing the risk of residual contamination.

Optimized Techniques for Metallographic Polishing

The metallographic polishing workflow typically includes sectioning, mounting, grinding, and polishing. Polishing is generally divided into two main stages:

• Coarse Polishing: Also known as raw polishing, this initial phase removes bulk surface irregularities and prepares the sample for fine finishing. For this step, Baikowski® offers Baikalox® DF500S, a corundum slurry formulated in the USA with fused alumina and GE1 alpha alumina. Corundum’s high hardness and angular morphology enable efficient and aggressive material removal, making it ideal for early-stage metal surface preparation.
• Finishing Polishing: This final stage aims to achieve a flawless, mirror-like surface suitable for accurate microstructural analysis. Baikowski®’s Baikalox® CR30F, BA105, and BP12MAR powders are particularly suited for soft metals such as aluminum and copper. Other Baikalox® references—such as GE6, GE15, CR16, and CR15—as well as diamond-based formulations, can be selected depending on the metal type and polishing step.
  Please contact our experts to identify the most suitable product for your specific needs.

Our evaluations here have been carried out on soft metals using mechanical polishing systems. The process involves progressively finer abrasives, typically following an initial corundum or diamond grinding stage.

Metallography applications

Metal polishing and metallograhy are crucial across diverse industries and research fields that demand precise material characterization and analysis, including:

• Aerospace and Automotive: Ensuring the integrity and performance of critical components.
• Electronics and Semiconductor Manufacturing: Facilitating the development of advanced materials and the assessment of microstructural properties.
• Biomedical: Supporting the development and quality control of metallic implants and devices.
• Watchmaking: Ensuring the quality and aesthetic appeal of metal components in watches, contributing to both durability and visual appeal.

Need help selecting the right Baikalox® product? Contact us!
Our experts will provide tailored advice to ensure you achieve the highest quality and precision in your metallographic preparations. Let’s innovate together!

Do not hesitate to have a look to our White Paper about our Solutions for superior intermediate and final polishing

Baikowski is at the forefront of innovation in materials science. Our products enable research and technological advancements in the field of technicl ceramics. Among the applications, there is the development of graphene oxide (GO) composite membranes anchored on α-alumina substrates as mentioned in the following scientific publication « Composite GO/Ceramic Membranes Prepared via Chemical Attachment: Characterisation and Gas Permeance Properties. »

By providing a stable and inert platform for GO deposition, the substrates enable the creation of composite membranes with finely tuned pore structures and enhanced separation capabilities in this study, essential for industrial applications.

The porous ceramic substrates made with our High Purity CR6 Baikalox® powder, provide the necessary resistance in high-temperature and corrosive environments where polymeric membranes will fail.

Potential Applications of Composite GO/ceramic membranes

These membranes exhibits enhanced stability and permeance, as well as tailored surface properties that can be employed in various industries to address critical separation and filtration challenges such as :

• 🌟 Gas Separation: The composite membranes are suitable for applications in industrial gas separation processes, purification of natural gas, and carbon capture technologies thanks to their ability to selectively permeate certain gases while retaining others.
• 🌟 Water Treatment: The hydrophilic and hydrophobic modifications enabled by chemical linkers such as PDA, GPTMS, and APTMS allow the membranes to effectively separate contaminants from water. This application is particularly relevant for wastewater treatment, desalination, and the removal of organic and inorganic pollutants from water sources.
• 🌟 Chemical Processing: The composite membranes’ resistance to chemical products and thermal stability make them suitable for the separation of organic solvents, recovery of valuable chemicals, and purification of reaction products.
• 🌟 Energy Sector: The selective permeation properties can be harnessed to separate hydrogen from other gases, which is a critical step in producing high-purity hydrogen for fuel cells and other energy applications.
• 🌟 Environmental Protection: By enabling the effective separation of harmful gases and pollutants, these membranes can help reduce emissions and treat industrial effluents, supporting cleaner and more sustainable processes.

CR6 High-Purity α-Alumina Powder Benefits

CR6 is a  powder of our Baikalox® range of products, well known for its fine particle size and excellent sintering properties.

These characteristics make it an ideal material for creating dense and robust ceramic supports, which are essential for high-performance composite membranes.

The specific properties of CR6 in that application include:

• 🌟 High Purity: this characteristic ensures minimal contamination, which is crucial for maintaining the integrity of the ceramic substrates and the GO layer deposited on them.
• 🌟 Controlled Particle Size Distribution: It contributes to the creation of uniform macroporous structures. This uniformity is essential for consistent membrane performance, as it influences both gas and water permeance.
• 🌟 Chemical Compatibility: compatibility of CR6 with various chemical linkers, such as polydopamine (PDA), 3-Glycidoxypropyltrimethoxysilane (GPTMS), and 3-Aminopropyltrimethoxysilane (APTMS), facilitated the effective anchoring of GO layers onto the ceramic substrates.
• 🌟 Excellent Sintering Behavior: It allows the creation of mechanically strong and thermally stable supports.

In the referenced study, custom-made α-alumina disks with a ~2 mm thickness and a 22 mm diameter were employed as substrates. The disks were fabricated by pressing the CR6 alumina powder in a custom-made mold and sintering at 800°C for 30 hours and further at 1180°C for 2 hours. One side of the disk was polished until no obvious scratch was observed under visual inspection with a light microscope.

How CR6 Alumina Contributes to Membrane Performance?

One of the primary challenges in composite membrane technology is ensuring strong and stable adhesion of GO layers to ceramic substrates.
The success here is mainly due to :

• 🌟 Enhanced Stability: The CR6-based substrates have showed remarkable stability, maintaining their structural integrity and performance under various conditions.
• 🌟 The smooth and polished surface: these surface characteristics have ensured optimal interaction with the modifying agents (PDA, APTES, GLYMO) and the graphene-based nanocomposites.
• 🌟 Thickness: The substrates have enabled the formation of composite membranes with precise thickness control, optimizing the membrane for different separation applications.

Our high purity CR6 alumina has proven to be a critical component in the advancement of composite membrane technologies. Its superior properties facilitate the creation of reliable and high-performing membrane supports, enabling the successful integration of graphene-based nanocomposites.

This synergy between high-purity alumina and advanced nanomaterials opens new possibilities for applications in gas separation, water purification, and other fields requiring durable and efficient membrane solutions.

Learn more on CR6 composite membrane application in the following study : A Combined Gas and Water Permeances Method for Revealing the Deposition Morphology of GO Grafting on Ceramic Membranes

 

The quality and performance of our powders are widely recognized in various ceramic applications. A comprehensive PhD thesis titled “Printability of Ceramic Pastes by Robocasting: Application in Solid and Multi-Component Materials” has been completed by Mathilde Maillard in 2022.

The aim of the project was to develop single- and multi-material ceramic parts (zirconia and alumina) with the least possible consumption of materials and energy. For this reason, additive manufacturing but also microwave heating sintering for consolidation and post-drying were selected.

This research has been instrumental in achieving significant progress in this technique and demonstrating how Baikowski® powders for 3D printing applications contribute to the production of complex geometries and robust ceramic structures.

More information available in our white paper dedicated to
3D printing advanced materials

Robocasting characteristics

Robocasting, aslo entitled Direct Ink Writing, was chosen over other 3D printing methods because of its potential to produce gradient multi-materials. This technique involves extrusion-based additive manufacturing, allowing for precise layering of ceramic materials that make intricate shapes and customized components possible.

The project aimed at optimizing the composition and processing parameters of ceramic pastes to achieve superior print quality and mechanical properties.

Baikowski® High Purity Alumina and Zirconia Powders

The spray-dried powders were delivered without binder and with a small particle size in order to produce homogeneous inks with suitable rheological characteristics for extrusion.

Baikalox® High Purity Alumina WA15

1. • Specific Surface Area: 23.6 m²/g
   • Particle Size Distribution (after deagglomeration):
     • D10 = 0.07 µm
     • D50 = 0.09 µm
     • D90 = 0.12 µm
   • Purity: Very low impurity levels, ranging from 0.005% to 0.084%

Baikalox® Zirconia Yttria 3 mol% BSZ3Y

1. 1. • Specific Surface Area: 14.1 m²/g
      • Particle Size Distribution (after deagglomeration):
      • D10 = 0.09 µm
      • D50 = 0.15 µm
      • D90 = 0.28 µm

Advantages of our 4N high purity powders with Robocasting Process

Printability and Rheological Properties: The powders demonstrated excellent dispersion and stability in the ceramic pastes. The rheological properties of these pastes were meticulously adjusted to ensure smooth and continuous extrusion during the robocasting process.
The study showed that by optimizing the solid loading and binder content, the desired viscosity and thixotropy were achieved, enabling compliant  shapes of the printed structures.

Structural Integrity and Mechanical Properties: One of the significant achievements of the study was the successful production of dense and mechanically robust ceramic parts. The ceramic structures exhibited high compressive strength and minimal shrinkage upon sintering.

Complex Geometries and Surface Finish: The ability to produce complex geometries with fine details is a critical requirement in additive manufacturing that Baikowski® powders have helped with.
Thanks to the optimized particle size distribution and spherical morphology of the powders, the surface finish of the printed parts was notably smooth, with minimal layer lines.
This characteristic is particularly beneficial for applications requiring precise dimensional tolerances and superior surface quality.

Ceramic 3D Printing Possible Applications With Baikowski® Powders

The ceramic quality achieved in this project with the robocasting method opens new avenues for Baikowski® powders where precision and performance are critical, such as:

Aerospace and Defense: The high strength and thermal stability of ceramic parts produced with our powders can withstand harsh conditions and maintain structural integrity in high-stress environments, including critical structural applications.

Biomedical Devices: The biocompatibility and excellent mechanical properties of the ceramics obtained open new avenues in the biomedical field. Custom implants and scaffolds with complex geometries can be produced. The smooth surface finish and high precision are particularly advantageous for reducing wear and enhancing the longevity of implants.

Electronics and Energy: Our powders enable the manufacture of ceramic parts with precise shapes and dimensions, insulating properties and high thermal stability, critical for electronic devices and energy storage systems.

The study underscores the significant advancements in robocasting 3D printing achievable with Baikowski® powders. The superior printability, structural integrity, and ability to create complex geometries position these powders as a valuable resource in various high-performance applications.

As additive manufacturing continues to evolve, Baikowski® remains at the forefront, driving innovation and expanding the possibilities in ceramic fabrication.

See all  the details in the PhD thesis (only in French)

Adaptive Driving Beam (ADB) is a smart system that can automatically adjust the light distribution of the headlights according to the traffic conditions, such as the presence of oncoming vehicles or pedestrians. By creating a glare-free area around vehicles, ADB can provide optimal illumination at long distances for the driver without dazzling other road users, enhancing both safety and comfort at night. ADB technology rely on perception systems that gather data, software controls that trigger an appropriate response, and advanced headlamp optics incorporating YAG converters to carry out the command.

Light conversion phosphors role in the solid-state lighting and ADB technology?

The light source is a key component for ABD, which is usually based on LED (light-emitting diode) technology and light changes are mainly controlled with a LED matrix design.

If LED have efficiency, long lifetime, low power consumption and fast response advantages over conventional halogen or xenon lamps, they also have color light rendering and thermal stability challenges. For high-power applications such as ADB, thermal stability and luminescent efficiency of phosphors can overcome these drawbacks.

Indeed, light conversion phosphors are materials that can absorb light of a certain wavelength (usually blue or near-ultraviolet) and re-emit light of a different wavelength (usually yellow or red). By combining the original and the converted light, white light with a desired color temperature and color rendering index can be obtained. The ideal color temperature for headlight should be close to the sunlight (around 5000K-6000K) in order to provide optimal visibility for human eyes.

One of the most widely used light conversion phosphors for white LEDs is YAG:Ce3+ (yttrium aluminum garnet doped with cerium ions) that efficiently convert blue into yellow light, resulting in a warm white light with a high luminous efficacy. By producing a high brightness and contrast ratio, it helps to create a clear and sharp image on the road.

Baikowski® high crystallinity, phasic and chemical purity submicronic YAG:Ce powder offers optimized particle size and distribution that allows the production of YAG-based converters with outstanding performances such as:

• 🌟 High efficiency with minimal energy wasted as heat and high light-performance from the input source
• 🌟 A quick and accurate response to the input signal for precise adjustments.
• 🌟 Exceptional stability in both light color and brightness

Fully compatible with nanostructured blue diodes and various LED chip designs, our YAG nanophosphors enable device miniaturization>

Learn more about Baikowski® unique submicronic YAG powders

Doped YAG for high-performance ADB lighting

By doping, enhanced performance of YAG:Ce3+ can be achieved. Here are some examples that could comply with your ADB lighting specification needs:

• 🌟 Color rendering: Doping YAG:Ce3+ with Tb3+ (terbium ions) allows a broader emission spectrum that improves the color rendering index of the white light.
• 🌟 Emissive properties and stability: the addition of gadolinium (Gd3+) ions as a codopant ensures consistent color and brightness
• 🌟 Quantum efficiency: Europium codoping can boost the quantum efficiency of the YAG:Ce phosphor, resulting in enhanced light output

Do not hesitate to contact our commercial and R&D teams for tailored YAG design.

 

The exploration of combining ceramic matrices with reinforcing fibers has started in the 1980s with the aim of creating advanced material composites with high temperature resistance and lightweight properties.

It was primarily driven by the aerospace industry’s need to enhance the performance of vital components like turbine blades, thermal protection systems (TPS), structural elements, brakes and more, as well as to decrease fuel consumption.

As the aviation industry continues to shape the future and work towards decarbonization, Ceramic Matrix Composites (CMCs) play a crucial role and are experiencing fast growth.

Baikowski®, at the forefront of  high-performance Ox/Ox CMC material development, has actively contributed to this paradigm shift. These CMCs offer temperature stability, low density, hardness, wear resistance and above all, they are not sensitive to oxidation compare to other CMCs.

Moreover, thanks to constant innovation in decarbonizing our manufacturing processes, Baikowski® oxide solutions benefit from a comprehensive Life Cycle Assessment. This involves assessing the environmental impact at each stage of the material’s life cycle to promote the implementation of sustainable practices and a more eco-friendly supply chain.

Baikowski® advanced 4N alumina & mullite solutions for Ox/Ox CMCs

Developing high quality Ox/Ox CMCs with superior performance properties for critical components required precise control over the characteristics of high purity alumina-based powders and slurries such as :

• 🌟 A well-dispersed and stable slurry, which is crucial for achieving the desired microstructure and mechanical properties of the final CMC, requires a fine and uniform particle distribution powder (< 1μm).
• 🌟 An optimal viscosity guarantees the desired structural integrity of the component
• 🌟 A high sintering reactivity allows for control over porosity and ensures rapid and efficient densification. These factors, in turn, impact CMC’s mechanical strength and thermal properties.
• 🌟 A densification temperature  kept as low as possible is determinant to preserve the structural and mechanical properties of the fibers and to ensure the overall stability of the CMC.
• 💡 Moreover, dopants can be added to improve specific characteristics, do not hesitate to contact us for tailor design. 💡

Among Baikowski® CMC offering, our SM8 powder and ready-to-use BA15-PSS slurry stand out, as well as our latest innovation SLAz, a High Purity Alumina Slurry with Nano-Zirconia Doping. Additionally, we have innovatively created a mullite solution for a better compatibility with mullite fibers.

See our 4N alumina & mullite solutions for CMCs

 

Ox/Ox CMC benefits for aero-engine applications

Combining oxide matrix with oxide fiber, such as alumina or mullite, results in better overall mechanical, physical and thermal properties. These CMCs offer reliable performance at temperatures up to 1,300°C, and no need for cooling air requirements, allowing the end products to be used in different aero-engine applications, such as combustion liners of gas turbine engines, heat shields and exhaust cones for example.

They have spurred innovation and efficiency in particular thanks to their :

Mechanical strength

Ox/Ox CMCs’ mechanical strength proves advantageous in engine components subjected to mechanical stresses, such as combustion liners. Their robust nature ensures liners to withstand the intense forces and rapid temperature fluctuations associated with the combustion process.

Corrosion Resistance

Corrosion resistance is also a cornerstone in fortifying the structural integrity of critical parts and significantly extend the lifespan and reliability of aerospace components exposed to harsh atmospheric conditions.

Over the years, CMCs in general and Ox/Ox CMCs have found applications beyond the aerospace industry, demonstrating their versatility and performance advantages in various fields, including the automotive, energy, electronics, defense and medical sectors.

For a deeper dive into our advanced materials for oxide CMCs and insights into what is an outstanding matrix and how is a slurry formulated for an Ox/Ox CMC of high quality, explore our dedicated white paper 👇

✅Why LED technology is a sustainable lighting & display solution?

Light Emitting Diodes (LEDs) have revolutionized various industries, by providing energy-efficient solutions with less environmental impact than traditional lighting for a wide range of applications, including display screens, car displays and lightings, electronics and smart devices.

Thanks to to the direct conversion of electrical current into light (optical radiation) within the semiconductor material, LEDs exhibit this remarkable level of efficiency. However, a significant portion of the electrical power is also transformed into heat during the process.

✅ What is the Role of High Purity Alumina, YAG & nanomaterials in advanced LED technology?

High Purity Alumina (HPA) plays an essential role in producing the substrate, which serves as a foundation for the LED chip, affecting its overall performance, thermal management, and efficiency. Thanks to its exceptional ability to resist high temperatures, conduct heat efficiently, and insulate against electrical conductivity, LED lights can operate at their maximum potential.

As a highly efficient heat-dissipating component, High Purity Alumina (HPA) has contributed to the LED technology sustainability. Indeed, by maintaining LEDs at optimal temperatures, they maximize their performance and extends their operational lifespan, about 30,000 hours, equivalent to 6 hours of daily illumination for 12 years.

HPA has also influences the optical performance of LED lights, particularly in applications demanding color purity and accuracy. Its uniform crystal structure enhance light diffraction and color consistency in applications like display screens and specialized lighting.

Beyond HPA, Baikowski® also manufactures phosphors, used among other things for generating a broader spectrum of colors, such as its submicronic YAG product that offers a natural-looking white light. For instance, it is used in white LEDs and plasma display panels, as well as adaptive headlights to create different colors and intensities of light depending on the driving situation and the environment.

💡 As technology continues to evolve, Baikowski® finely-tuned oxides solutions and Mathym® advanced nanomaterials, that offer high crystallinity and controlled specific surface area, will have a role to play in the progress of emerging optics applications like mini-LED and micro-LED displays.💡

Integrating the superior performances of Mathym® nanoparticles, such as zilight®  into nanoscale structures or coatings, not only enables the miniaturization of optical devices, but also facilitates integration with other technologies, paving the way for the development of compact and multifunctional  LED lighting solutions. Learn more about optical coating with zilight®, including case studies, in our dedicated white paper.

🌟 Whether it’s LED lighting or cutting-edge displays, Baikowski® group is here to cater to your specific needs.🌟

View optics and photonics related products

Designing easy-to-use solutions in order to meet our customer needs, processes and applications, is part of our know-how and DNA. Indeed, Baikowski® provides various ready-to-use oxides including:

spray-dried powders and slurries.

Powder deagglomeration

Several methods of powder deagglomeration are used according to the desired particle size and distribution.

• Jet milling is the easiest way to produce middle-size milled powders that offer a large size distribution composed of one or two populations.
• Ball milling is a size reduction technique using only mechanical forces that enables a lower size distribution than jet milling.
• Wet milling allows the production of smaller particle size and a narrower size distribution versus other milling methods.

Thanks to these different deagglomeration processes, Baikowski® has not only the ability to expand its product portfolio with products that offer specific physicochemical properties and a higher sintering reactivity, but also to control dispersion, morphology, composition, homogeneity at the powder grain level.

Ready-to-use and ready-to-press oxides benefits

Wet milling enables the design and production of ready-to-use slurries, spray-dried powders with or without binder and freeze-dried solutions.

Among the various benefits of ready-to-use or ready-to-press solutions, we can mention a
better flowability, an improved behavior while pressing ceramics and a perfect consistency of your final product. 

Generally speaking, slurries and spray-dried powders have helped our customers develop unique solutions in various markets including energy, battery, health or 3D printing, by allowing the design of innovative materials.

As noticeable examples:

• spray-dried powders have considerably improved the ceramic injection molding process by making the production of feedstocks easier.
• ready-to-use slurries have been a major breakthrough in the Semicon industry by ensuring the absence of large particle counts in the Chemical Mechanical Planarization (CMP) process.
• YbF3 nano-dispersions, already dispersed in the dental formulations, have allowed outstanding performances for restorative applications. Mathym®, the producer of nano-dispersions within the Baikowski ® group, is a key actor of this market.

Baikowski® 3N & 4N ready-to-use and ready-to-press offering

Taking into account all of the above, our GE9, GEA6, and BA15 high purity alumina products, as well as our ZTA/ATZ and spinel solutions are commercially available in slurry, spray-dry and ready-to-press forms.

Other products and custom designs upon request.

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How do we characterise and design powders and slurries thank to our in-house analytical skills?

Listen to Livia MARRA explanations, our Senior Project Manager, in this short video.

 

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” Hello, my name is Livia Marra. I have been working for Baikowski since 2012. I started as a trainee engineer before becoming a R&D project manager.

Baikowski is a 115-year-old company, specialized in high purity alumina and many other oxide powders.
Our headquarters and manufacturing plant are located in Poisy, in France. We have another manufacturing plant in the United States, a joint venture in Japan and several sales offices around the world.
Mathym joined us in 2019 and is specialized in nano-dispersions. This branch of Baikowski enables us to expand our product offering and expand in new markets such as the dental one.

We address several markets including automotive, electronics, medical, watch & jewelry, aerospace & defense and cover applications in ceramics, polishing and batteries.
With so many high-end applications, we have great analytical needs, either to respond to our client demands, or to anticipate their needs. That’s why we are always looking for ways to improve our products characterization. For this purpose, we bought the “Calvet Pro of Setaram” that provides us thermogravimetric and DSC analyses.

As an example, we use it to measure the moisture absorption of our alumina powders. In lithium-ion battery applications, we know we can’t have water as it would interfere with lithium metal. By figuring out the mass uptake by a powder during its exposure to a humidity air flow, we are able to calculate the absorption rate of a powder.

For catalytic applications, the device allows to inform customers on the acidity/basicity of our products, their ability to absorb different type of gas.

We can also assess the mass lost of a powder with blinder system or the decomposition temperature of a special product. In addition, we can carry out a synthesis knowing the transformation temperature of the powder.

As a conclusion, thanks to the flexibility of this device and our analytical skills, we can meet a lot of our customers’ expectations. ”

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