Gelcasting Technology for Honeycomb Ceramics

Gelcasting technolog is the second most mainstream technology in the field of honeycomb ceramics, second only to extrusion molding. It is suitable for producing thin-walled, high-pore-density, and complex honeycomb ceramic products.

Basic Principle

Based on the gel casting principle: Ceramic powder is mixed with organic monomers to form a low-viscosity, high-solids-content slurry. The finished product is then produced through steps such as injection molding, in-situ polymerization, demolding, and sintering.

Process Flow

Slurry Preparation: Ceramic powder (60-85% vol) + organic monomers + dispersant, solids content 50-65% vol.

Injection Molding and Geling: Using silicone/polyurethane molds, vacuum or pressure molding is performed, and gelation is carried out at 60-80℃ for 30-120 minutes.

Post-processing: Demolding and drying → Degreasing (500-600℃) → High-temperature sintering (1400-1600℃) → Post-treatment.

Technical Advantages

Structural Performance: Capable of producing products with wall thickness <0.1mm and pore density up to 1200 cpsi, offering strong shape adaptability.

Process Control: High dimensional accuracy (±0.5%), low defect rate, long mold life (200-500 cycles), and good batch stability.

Application Areas

Automotive Exhaust Purification: Ultra-thin wall carriers (0.05-0.07mm), gradient pore structures, composite structure carriers.

High-Temperature Filtration: Asymmetric structures (large pore support + micropore filtration), multi-layer composites, irregularly shaped filter elements.

Heat Storage and Catalysis: Three-dimensional interconnected pores, functionally graded materials, built-in flow channel design.

Market Prospects

This technology holds a unique position in the high-end, customized, and complex honeycomb ceramics field, with an expected annual growth rate of 15-20%. Key growth areas include:

China VI/Euro VI vehicle exhaust purification carriers

High-temperature flue gas ultra-low emission filter elements

Key components for new energy (hydrogen energy, fuel cells)

Specialty ceramic components for semiconductor manufacturing

Summary 

Gelcasting technology has improved the honeycomb ceramic manufacturing system, providing key technical support for high-end applications. With technological advancements and cost optimization, it will play a more important role in the field of specialty honeycomb ceramics, driving the industry towards high performance, multi-functionality, and customization, and marking a significant step towards precision manufacturing.