Experts in
Extrusion Technology for the Creation of
Advanced Ceramics

Pilot IS Advanced Ceramics are unique ceramic products made via the application of core technologies like kneading, extrusion molding, and firing that have been developed in the manufacturing of pencil leads for our mechanical pencils.These are high-density, high-strength, high-purity ceramics that have been finely molded and uniformly fired using our own specially developed extrusion molding equipment and firing know-how.

Process

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Shape Capabilities

An example of a micro porous ceramic extrusion.
Microporous Ceramics

High aspect ratio holes perforate a molded article in the extrusion direction. Typically, with fine holes (pores) of less than 1mm in diameter, it is difficult to achieve an aspect ratio (depth/inside diameter) of more than 5–10 using only machining. Extrusion molding technology, however, makes it possible to manufacture articles having micropore aspect ratios of 200 or more. Even articles with various thin or thick wall characteristics can be achieved.

Uses:
• Flow rate controllers
• Sensor holders
• Insulators (e.g., glass)

An example of a non uniform porous ceramic extrusion.
Non-Uniform Porous Ceramics

Porous ceramics can also be produced using micro-extrusion molding. Porosity of up to 70% can be set arbitrarily.

Uses:
• Filters
• Liquid holders
• Adsorption parts

An example of a  uniform porous ceramic extrusion.
Uniform Porous Ceramics

Pilot IS can produce porous ceramics where even hard-to-stabilize flow rates are achieved by through-holes formed in the extrusion direction. Tiny, high-precision and uniform holes are applied to achieve gas and liquid flow rate control. Unlike a typical porous body, extrusion-molded holes pass through the molded article linearly, enabling a uniform, stable flow rate, while minimizing pressure loss.

Uses:
• Semiconductor manufacturing equipment
- Filters
- Nozzles
- Baffle plates
- Flow rate controllers
- Microreactors

An example of a specialty shape ceramic extrusion.
Specialty Shaped Ceramics

Progress in Pilot IS Advanced Ceramic technology has made it possible to combine an abundance of different external and internal shapes, which can be utilized in new applications. For example, articles having a rectangular external shape and a circular internal shape, or a gear-like external shape and a circular internal shape are possible.

Ceramic Shape Capabilities

An example of a micro porous ceramic extrusion.
Microporous Ceramics

High aspect ratio holes perforate a molded article in the extrusion direction. Generally speaking, in the case of fine holes (pores) less than 1mm in diameter, it is difficult to achieve deep holes having an aspect ratio (depth/inside diameter) of 5-10 or more using machining. But extrusion molding technology makes it possible to manufacture articles having micropore aspect ratios. Articles with various wall thicknesses, from thin walls to thick walls, can be produced.

Uses:
• flow rate controllers
• sensor holders
• insulators (e.g., glass)

An example of a  uniform porous ceramic extrusion.
Uniform Porous Ceramics

Pilot IS can produce porous ceramics where even hard-to-stabilize flow rates are achieved by through-holes formed in the extrusion direction. Tiny, high-precision and uniform holes are applied to gas and liquid flow rate control. Unlike a typical porous body, extrusion molded holes pass through the molded article linearly, enabling a uniform, stable flow rate, while minimizing pressure loss.

Uses:
• semiconductor manufacturing equipment
• filters
• nozzles
• baffle plates
• flow rate controllers
• microreactors

An example of a non uniform porous ceramic extrusion.
Non-Uniform Porous Ceramics

Porous ceramics can also be produced using micro-extrusion molding. Porosity of up to 70% can be set arbitrarily.

Uses:
• Filters
• Liquid holders
• Adsorption parts

An example of a specialty shape ceramic extrusion.
Specialty Shaped Ceramics

Advances in Pilot IS Advanced Ceramic technology have made it possible to combine an abundance of different external and internal shapes, which can be utilized in new applications. For example, articles having rectangular external shape and a circular internal shape, or a gear-like external shape and a circular internal shape.

Materials & Specifications

Alumina

Excellent insulation and heat resistance, good thermal conductivity and extreme chemical resistance.

Aluminum Nitride

High thermal conductivity and electrical insulation properties that prevent distortion from heat.

Zirconia

High strength (toughness), excellent thermal properties and aesthetics.

Yttria Stabilized Zirconia

Oxygen-ion conductivity, excellent heat-shielding properties and doped with 8mol yttrium oxide.

Specifications

ID: from ø0.005mm

OD: ø0.2mm– ø10mm

Length: Up to 120mm

RA: As requested

Tolerance: As requested

Straightness: As requested

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Frequently Asked Questions

How does Pilot IS produce ceramics?

We use our integrated manufacturing plants in Japan and apply mechanical pencil lead extrusion molding techniques and expertise.

What kinds of ceramics can Pilot IS make?

Using extrusion molding technology, we can produce ceramics that have extremely small holes and shapes that are long and thin.

What raw materials does
Pilot IS use?

We mainly focus on high-purity alumina, but also zirconia, aluminum nitride and yttria stabilized zirconia.

What is the production lead time?

Pilot IS can produce most ceramics* in 60 – 90 days after receiving a purchase order. *The lead time is based on the product dimensions.

Where are the advanced ceramics from Pilot IS made?

All of our ceramics are made by Pilot IS in our facilities in Hiratsuka, Japan.

What straightness and tolerances can Pilot IS achieve?

Please contact us for more information.

Industries Served

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Manufacturing

Technology

Medical

Industrial Machinery

Automotive

Accessories

CASE STUDIES

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Innovative Solutions for
Global Applications
Pilot corporation brings over 100 years of manufacturing innovation and experience to the global marketplace. This heritage is the cornerstone of Pilot Innovative Solutions (Pilot IS) offering exceptional technological advancement and the precision that comes from a century of ground-breaking engineering.