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Pilot Corporation offers high precision extrusion manufacturing techniques to create extremely tight tolerances with very thin walls for length over diameter ceramic applications.
Extrusion is a process by which long, straight products such as rods and pipes with various cross sections can be produced continuously. The technology allows capillaries with a hole diameter of 20 µm without boring or machining.
High precision small diameter ceramic capillaries are perfectly extruded in outer diameters ranging from 0.3 to 5 mm. The length can be cut to meet customer specifications but it generally ranges from 0.3 mm to 120 mm.
± 0.5 µm Outside Diameter
± 0.3 µm Inside Diameter
> 100 µm Wall Thickness
< 120 mm in Length
The number of fine holes produced with extrusion technology is dramatically increased compared with conventional sintering that produces 200 µm versus 20 µm using extrusion. This technology can also produce ceramic capillaries with hundreds of uniform holes avoiding pressure loss through holes.
Extruding technology utilizes a high density ceramic that is made with low porosity and controlled grain sizes. Alumina and zirconia are the most common materials used in the extrusion process.
| Dimension | Tolerance | Microns | MM | Inches | Mils |
|---|---|---|---|---|---|
| Outside Diameter | ± 2% | n/a | n/a | n/a | n/a |
| Inside Diameter | ± 3% | n/a | n/a | n/a | n/a |
| Concentricity | 50 µm | 50 | 0.05 | 0.002000 | 2.0000 |
| Eccentricity | 0.01 µm | 100 | 0.1 | 0.004000 | 4.0000 |
| Surface Roughness | 2 µm | 2 | 0.002 | 0.000080 | 0.0800 |
| DIMENSION | TOLERANCE | MICRONS | MM | INCHES | MILS |
|---|---|---|---|---|---|
| ACCURACY OF EXTRUDED PRODUCTS | |||||
| Outside Diameter | ± 2% | n/a | n/a | n/a | n/a |
| Inside Diameter | ± 3% | n/a | n/a | n/a | n/a |
| ACCURACY BEFORE SECONDARY PROCESS | |||||
| Concentricity | 50 µm max | 50 | 0.05 | 0.002000 | 2.0000 |
| Eccentricity | .01 mm max | 100 | 0.1 | 0.004000 | 4.0000 |
| Surface Roughness | 2 µm max | 2 | 0.002 | 0.000080 | 0.0800 |
| ACCURACY AFTER SECONDARY PROCESS | |||||
| Outside Diameter | ± 0.5 µm | 0.5 | 0.0005 | 0.000020 | 0.020 |
| Inside Diameter | ± 0.3 µm | 0.3 | 0.0003 | 0.000012 | 0.012 |
| Concentricity | 2 µm max | 2.0 | 0.0020 | 0.000080 | 0.080 |
| Surface Roughness | 0.1 µm max | 0.1 | 0.0001 | 0.000004 | 0.004 |
| Eccentricity (P) | 0.05 mm max | 50.0 | 0.0500 | 0.002000 | 2.000 |
| Eccentricity (S) | 1~2 µm max | 2.0 | 0.0020 | 0.000080 | 0.080 |
| Surface Roughness (S) | 0.1 µm max | 0.1 | 0.0001 | 0.000004 | 0.004 |
| PHYSICAL DIMENSION | LIMIT | ||||
| Length Minimum | 0.3 mm | 300 | 0.30 | 0.0120 | 12.00 |
| Length Maximum | 120 mm | 120,000 | 120.00 | 4.7000 | 4700.00 |
| Outside Diameter Maximum | 5 mm | 5,000 | 5.00 | 0.2000 | 200.00 |
| Inside Diameter Minimum | 0.01 mm | 10 | 0.01 | 0.0004 | 0.40 |
| Wall Thickness Minimum | 5 µm | 100 | 0.10 | 0.0040 | 4.00 |
| Rods and Single Bore Tubes | |||||
| Outside Diameter Minimum | 0.3 mm | 300 | 0.30 | 0.0120 | 12.00 |
| Multi Bore Tubes (2 to 6) | |||||
| Outside Diameter Minimum | 0.5 mm | 500 | 0.50 | 0.0200 | 20.00 |
(P) = Precision tolerance after secondary processing
(S) = Super Precision tolerance after secondary processing
The dimensions, accuracies and tolerances listed in the chart above are examples based on using high quality alumina or zirconia. Actual results will vary dependent on the material selected and the geometry of the product design.
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