Producing ceramic products is a complex process and is completed in different stages. Every stage needs the absolute precision and expertise of a

. Advanced techniques and materials are used in the process.

Selecting the raw material

It all starts with obtaining the right kind of material to make the product. It should be of high quality. Ideally, the best ceramics are obtained from clay materials with moderate impurities. These are obtained from nature as clay materials, which are then turned into extremely fine and pure powders by using chemical synthesis techniques.

Usually, ceramics produced from silica, quartz, sand, aluminosilicate, and feldspar are considered to be the best, with enhanced ceramic properties that make them electricity and abrasion-resistant.

Beneficiation

The next important step of ceramic product manufacturing is called beneficiation. This is actually a step that refines the raw materials that are available naturally. There are different techniques of beneficiation, such as purification, comminution, calcining, and others. It is usually done at the mining locations but may also be carried out in a processing facility. The main objective of this process is to remove the impurities from the material.

Mixing

This process is followed in pug mills and refers to the creation of a uniform material by blending different powder components of ceramic. This process actually facilitates physical and chemical shaping. In addition, there are different types of processing aids or binding agents are included in this stage.

Forming

You will get ceramics in different forms, which are given during the forming process. Different forming techniques are used to manufacture ceramic products. For example, in the slip-casting process, liquid clay or slip is used in a plastic mold, and water is drained from the mold walls. This leaves a solid layer of clay inside the mold. This clay is then removed when it is dried and becomes firm.

There are also a few other procedures followed during the forming stage, such as tape casting, gel casting, and injection molding, where organic substances are added to the ceramic mix. This helps give any shape to the ceramic material as desired.

However, the specific type selected for production will depend largely on the type and application intended.

Green Machining

This step involves giving complex shapes to the ceramic when it is “green” or uninterred by using handling and clamping techniques.

Drying

This process refers to the removal of water from the clay that was added during forming. The rate may vary according to the processing variables and material characteristics.

Thermal process

High temperature is used in this stage to create heat-resistant ceramic. Firing is a common technique followed by placing the material in a sintering oven to harden it.

Glazing

In this process, a liquid glaze is usually sprayed over the surface. Brushing or pouring are also other techniques for glazing ceramic.

Glaze firing

In this stage, the glazed ceramic is loaded and fired in a kiln at a high temperature to melt the silica. Then, it is cooled down to fuse perfectly with the glaze.

Conclusion

Usually, a manufacturer will follow a strategic process involving specific steps to produce the best products with a guarantee of durability and quality.