Using advanced equipment, Du-Co has two ceramic manufacturing capabilities in facilities capable of producing millions of parts per day. Pressed ceramics can be manufactured up to 5″ in diameter and extruded ceramics can be maufactured up to 3″ in diameter. Ceramic parts are produced in Steatite Ceramic, Cordierite Ceramic, Magnesium Oxide Ceramic, Mullite Ceramic, Alumina Ceramic and Forsterite Ceramic. Du-Co’s processes are dry pressing, extrusion, secondary machining, glazing and both centerless and flat grinding. Du-Co offers technical engineering expertise to assist with your design and ceramic material selection enabling Du-Co to produce high quality technical ceramics at competitive pricing in the quantities you require. With this capability, Du-Co serves both high and low technical ceramic volume applications.
Precision Ceramic Production Operations
Steatite Ceramic, Cordierite Ceramic, Forsterite Ceramic, Mullite Ceramic , Magnesium Oxide Ceramic and Aluminum Oxide Ceramic are among the wide varieties of raw ceramic materials used in the production of Du-Co ceramic insulators. Materials are tested and monitored throughout the production process. Please contact us to assist you with design and material selections. We may be able to offer a lower cost alternative to what you use now with a custom material. As one example, we have used a cordierite variant material as a lower cost substitute for the more expensive mullite ceramic, while maintaining the required properties for the ceramic component.
Ceramic Production Processes
- Extruded Sections: Extruded Ceramic products with regular and linear shapes are produced using the extrusion process. Du-Co extrudes ceramic shapes to a maximum of 3 inches in diameter and 50 inches in length using extrusion equipment engineered and built in-house.
- Automatic Press Parts: Irregularly shaped or multi-level ceramic components are produced with automatic pressing equipment. Some of the most intricate shapes can be achieved on Du-Co’s custom-designed presses, which can produce ceramic components to a maximum of 5 inches in diameter and 2 1/2 inches thick.
- Machined Parts: Many features that cannot be incorporated into the die design are machined into ceramic components after extrusion or pressing. Du-Co can drill, tap, slot, thread, machine and groove to exact tolerances prior to firing.
Glazing, Firing, and Finishing Ceramics
Du-Co ceramic insulators can be glazed to your specifications before or after firing. Our glazing machines are monitored and controlled to apply glaze to the designated area of the ceramic parts with precision and uniformity. Glazed ceramic and unglazed ceramic parts ultimately are transferred to Du-Co’s gas-fired tunnel or periodic kilns for the firing process.
Every phase of the firing process, from initial heat-up through the cooling of the finished ceramic product, is continually monitored and controlled. This uniformity of firing helps ensure the dimensional stability of ceramic products, as well as the electrical and mechanical properties.
When necessary to meet customer specifications, a variety of finishing operations can be carried out following the firing of ceramic products. A tumbling process can be utilized to obtain a desired surface finish for certain parts.
Toll Spray Drying Services
Du-Co Ceramics is a full service toll spray dried powder provider. With multiple dryers Du-Co has the capability to process small quantities for research and development, as well as high volume quantities.
Should your company have a requirement for a free flowing powder form material, Du-Co Ceramics will be happy to discuss your specific need and review the most economic approach to meet your requirements.
Quality & Reliability
After firing, finished parts are subjected to a final quality audit to ensure accordance with blueprint specifications. We firmly believe, however, that quality cannot be inspected into the final product. Quality is managed into Du-Co ceramic insulators through our rigid control of the entire production process.
Du-Co’s experienced technical ceramic engineers and technicians are the driving force behind our total quality assurance program. Our experience enables us to identify critical control variables throughout the manufacturing process, from the analysis of raw ceramic materials to the firing of finished ceramic insulators. Our quality control teams use sophisticated control systems to continually monitor and regulate equipment capability to ensure the finished ceramic product meets required tolerances. Final inspections and quality audits serve only to confirm that systems are operating properly and products are conforming to specifications.
We are ISO 9001-2015 Certified.
Du-Co Ceramics Company will meet the requirements of our customers. This principle, the continued hard work and dedication from loyal employees coupled with ongoing engineered innovations is the bedrock on which Du-Co Ceramics Company will maintain its ability to manufacture superior ceramic components for its valued customers around the globe.