Washout Ceramic: a paradigm shift in tooling for advanced composites

Next-Level Strength and Performances

Washout Ceramic establishes a new industry benchmark for water-soluble materials used in sacrificial tooling. This advanced formulation boasts a flexural strength of 8 MPa, which can be further enhanced to an impressive 15 MPa through the application of an optional coating. This remarkable strength represents a six to eightfold increase compared to CONCR3DE's previous generation of water-soluble materials, unlocking the potential for significantly larger and more intricate part designs. Furthermore, the alumina content within Washout Ceramic imparts a Coefficient of Thermal Expansion (CTE) of approximately 7 ppm/°C.

This low CTE ensures exceptional thermal dimensional stability, a critical factor when dealing with the temperature variations inherent in composite curing processes. Demonstrating its readiness for demanding manufacturing environments, Washout Ceramic exhibits robust resistance to temperatures up to 180°C, making it fully compatible with autoclave curing processes. The material also delivers high dimensional precision, maintaining accuracy to within <0.2 mm per meter, ensuring the fidelity of even the most complex tool geometries. A key feature of Washout Ceramic is its complete water solubility. Removal of the tooling after composite curing is efficiently achieved using standard tap water, streamlining post-processing workflows and eliminating the need for harsh chemical solvents. These combined enhancements position Washout Ceramic as the ideal solution for manufacturing larger, more intricate composite parts that are subject to significant temperature fluctuations during the curing cycle.

Washout Ceramic material is designed for seamless integration with CONCR3DE's range of 3D printers. This plug-and-play compatibility ensures a smooth and efficient workflow for users. The process includes specifically formulated consumables: PS1007 Cer Powder, a fine, high-strength ceramic powder providing the foundational material; BS1003 Sol-C Aqueous Binder, an eco-friendly and non-toxic binding agent that solidifies the ceramic powder; SS1002 Washout Coating, an optional protective barrier that can be applied to further enhance strength and provide an alternative to Teflon tape; and FA1001 Aqueous Flush, a solution designed to support efficient post-processing and material removal. Washout Ceramic is fully compatible with CONCR3DE's Armadillo Gray, Armadillo White, and Elephant Gray printers. For optimal results, a suggested layer height of 100–200 microns is recommended, with the specific choice depending on the desired balance between mechanical strength and printing speed.

Applications of Advanced Composite Tooling Across Industries

Washout Ceramic has been specifically optimized for a wide range of advanced composite tooling applications across various industries. Its unique properties make it ideally suited for:

• the creation of tooling for composite layups utilizing both carbon and glass fiber;
• the production of complex aerospace manifolds and ducts with intricate internal geometries;
• the fabrication of automotive tanks and exhaust systems requiring high temperature resistance and dimensional accuracy;
• and as mandrels and sacrificial molds for creating complex internal channels within composite structures.

Washout Ceramic offers versatility and performance that industries to explore new possibilities in composite design and production.

Innovation meets sustainability

CONCR3DE's commitment to sustainability is deeply embedded in the design of Washout Ceramic. Unlike traditional solvent-based sacrificial tooling materials, Washout Ceramic is fully water-washable and relies on sustainable binders. This fundamental difference makes it a significantly cleaner and safer choice for modern composite manufacturing operations, reducing environmental impact and improving workplace safety. Furthermore, both the binder and the ceramic powder used in Washout Ceramic are non-harmful to users and the environment. Demonstrating a commitment to circular economy principles, the material can be recycled and reused in certain workflows, minimizing waste and maximizing resource utilization. Importantly, all components of the Washout Ceramic system are water-dispersible and degrade safely without leaving harmful residues, further underscoring its eco-friendly profile. By choosing Washout Ceramic, manufacturers can achieve high performance while simultaneously advancing their sustainability goals.

CONCR3DE's Washout Ceramic represents a significant advancement in water-soluble 3D printing materials for sacrificial tooling. Its exceptional strength, dimensional accuracy, autoclave compatibility, and water-based removal process provide a compelling solution for the challenges of manufacturing complex composite parts. Moreover, its inherent sustainability makes it a responsible choice for the future of advanced composite manufacturing. Washout Ceramic empowers industries to create stronger, smarter, and more sustainable composite structures.