Ceramic Terminal Block - Photocured Ceramic 3D-Printed High-Temperature Resistant Complex Structures

Facing challenges

New energy vehicle battery packs, photovoltaic inverters, and rail transit electrical cabinets require high-temperature-resistant, high-insulation custom ceramic terminal blocks. Traditional dry pressing can only produce simple cylindrical or square shapes; complex custom geometries require multi-step assembly with a yield rate of just 60%. Precision machining of ceramics demands diamond tools, resulting in high costs and low efficiency, while holes smaller than 0.5mm cannot be machined. Mold development costs range from 20 to 50 thousand USD, making small-batch customization prohibitively expensive. Product development cycles extend up to 3-6 months.

Solutions

SLA ceramic 3D printing uses alumina ceramic slurry (Al₂O₃ content ≥ 85%, solid content ≥ 78%) to directly form complex curved surfaces, micro-holes (≥ 0.3mm), slots, threads, and other fine structures on irregular ceramic terminal connectors. Layer thickness of 0.05mm ensures dimensional accuracy. After debinding and sintering, the parts achieve a density ≥ 96%, withstand temperatures up to 1600°C, with dielectric strength ≥ 18kV/mm and flexural strength ≥ 380MPa. The process supports monolithic fabrication without assembly, enables low-volume customization without tooling, and reduces unit cost by 70%.

Achieve Results

Reduced development cycle for custom ceramic terminal blocks from 3-6 months to 2 weeks; lowered unit cost from 500 yuan to 150 yuan; achieved micro-hole precision of ±0.05mm; increased first-pass firing yield from 60% to 95%；successfully deployed in a leading new energy vehicle manufacturer's battery pack high-voltage connector, passing thermal endurance tests at 1500℃/100 hours with insulation performance exceeding traditional processes by 30%；cumulative supply of 5000+ units with zero failures.

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