Our Capabitlies
All our products are in-house manufacturing, ensuring consistent quality, and timely delivery
Step 01: Design & Drawing
The process begins with our dedicated design team collaborating closely with clients to translate their ideas into precise technical drawings. Using advanced CAD software, we develop detailed 2D and 3D models that cater to the specific requirements of each project. These designs undergo multiple review cycles to ensure accuracy, functionality, and compatibility with production capabilities. Every detail, from dimensions to tolerances, is meticulously verified, laying a strong foundation for a seamless manufacturing process that meets client expectations.
Step 02: Slurry Melting & Stirring
This crucial step involves preparing the ceramic slurry by melting and blending premium-grade raw materials. Using advanced mixing equipment, the slurry is carefully stirred to achieve the ideal consistency and homogeneity. Key parameters like temperature, viscosity, and particle distribution are strictly monitored to ensure the slurry meets stringent quality standards. This uniform mixture forms the backbone of the ceramic product, ensuring strength, durability, and precision in subsequent stages of production.
Step 03: Forming Process
Once the slurry is prepared, it is carefully poured into precision-engineered molds or forming bowls. Using techniques such as slip casting or pressing, we shape the ceramic into its desired form with exacting accuracy. The formed pieces are handled with care to prevent structural damage, and they are systematically loaded onto carriers or trays. This stage sets the structural foundation of the ceramic components, ensuring consistency and precision as they move through the production line.
Step 04: Load Blanks on Ceramic Firing Tray
The prepared ceramic blanks are loaded onto specially designed firing trays, ensuring proper alignment and spacing to minimize deformation during firing. Our team meticulously arranges the blanks to optimize kiln capacity while ensuring even heat distribution. This step is vital to maintaining the dimensional accuracy and structural integrity of the components as they advance through the high-temperature sintering process.
Step 05: Dewaxing Process
The dewaxing stage involves removing any residual wax or binders from the formed ceramic pieces. Using controlled heat treatments in specialized equipment, the process eliminates impurities while preserving the integrity of the ceramic structure. This step is critical for ensuring the material’s purity, enhancing its mechanical properties, and preparing it for high-temperature sintering. By removing these remnants, we create a cleaner, stronger base for the final product.
Step 06: Sintering Process
During sintering, the ceramic components are fired in high-temperature kilns, where the particles bond together to achieve maximum strength and durability. Our kilns are equipped with state-of-the-art controls that manage temperature profiles and firing durations with precision. This process not only enhances the product’s structural integrity but also ensures excellent thermal and chemical resistance. By the end of this stage, the ceramics have reached their final form with outstanding performance characteristics.
Step 07: Vibratory cleaning
After sintering, the ceramics undergo vibratory cleaning to refine their surfaces. Utilizing specialized machinery, this step removes residual impurities, sharp edges, and irregularities from the product. The cleaning process ensures a smooth finish, enhancing both the aesthetics and functionality of the ceramic components. Each piece is carefully inspected post-cleaning to confirm that it meets our high-quality standards and is ready for the final inspection phase.
Step 08: AI & Manual Quality Inspection
To maintain the highest standards of quality, every product undergoes a dual-inspection process combining AI technology with manual checks by skilled technicians. Advanced AI systems detect microscopic defects, while manual inspections focus on dimensions, tolerances, and overall functionality. This thorough evaluation ensures that only products meeting our stringent quality criteria proceed to the packaging stage, guaranteeing reliability and excellence for our clients.
