Projects | INNOVACERA

Direct Bonded Copper Ceramic Substrates

Direct bonded copper (DBC) ceramic substrates create robust thermal and electrical interconnection platforms by bonding oxygen-free copper layers (0.1-0.6mm thick) to ceramic substrates like alumina or aluminum nitride through high-temperature oxidation processes. These substrates handle extreme current loads (300A+) and power densities exceeding 500W/cm² in IGBT modules, MOSFET arrays, and thyristor packages. Innovacera’s DBC process achieves exceptional bond strength (>20 N/cm² peel strength) and thermal cycling reliability, making them ideal for automotive traction inverters, industrial motor drives, and renewable energy systems. The copper layers can be pre-patterned or chemically etched to create complex circuit geometries with minimal undercut and excellent edge definition. With thermal conductivity up to 200 W/mK (for AlN DBC) and dielectric strength >15 kV/mm, our DBC substrates outperform conventional PCB materials in high-voltage, high-frequency applications. Innovacera provides complete DBC solutions including design support, prototyping, and volume production for power electronic assemblies requiring superior thermal management and electrical performance.

High Performance Ceramic Substrates

Innovacera’s High Performance Ceramic Substrates provide superior thermal management, electrical insulation, and mechanical stability. Made from Al2O3, AlN, Si3N4, or ZTA, they withstand -55°C to 850°C thermal cycling while maintaining dimensional and electrical integrity. Ideal for power modules, LEDs, RF/microwave circuits, and semiconductors, with precise flatness, smooth surface, and customizable metallization for automotive, aerospace, telecom, and industrial applications.

Ceramic Grinding Media for Milling and Dispersion

Ceramic grinding media, such as Zirconia and Alumina balls, are essential for efficient milling, grinding, and dispersion processes. Compared to metal or glass media, they offer higher density, superior wear resistance, and minimal product contamination. This makes them ideal for producing fine particles in industries like paints, inks, minerals, and pharmaceuticals. Innovacera manufactures high-quality Zirconia and Alumina grinding media that optimize milling efficiency and ensure product purity.

Advanced Ceramic Blades for Industrial Cutting

Zirconia ceramic blades offer a significant performance upgrade over steel blades in industrial cutting and slitting applications. Their extreme hardness results in a cutting edge that stays sharp up to 10 times longer, reducing downtime and improving cut quality. They are also chemically inert and corrosion-proof, making them ideal for cutting film, foil, paper, and food products. Innovacera produces a wide range of standard and custom zirconia ceramic blades that deliver precision and longevity.

Ceramic Heat Sinks for Power Electronics Cooling

Ceramic heat sinks are an advanced solution for thermal management in power electronics, offering both high thermal conductivity and excellent electrical insulation. Materials like Aluminum Nitride (AlN) and Alumina (Al2O3) dissipate heat effectively while isolating components, making them ideal for LEDs, IGBT modules, and MOSFETs. Innovacera manufactures custom ceramic heat sinks that provide superior, reliable cooling performance, replacing traditional metal sinks where electrical insulation is critical.

Ceramic Injection Molding (CIM) for Complex Parts

Ceramic Injection Molding (CIM) is a manufacturing process that combines the design freedom of plastic injection molding with the superior properties of technical ceramics. It enables the cost-effective, high-volume production of small, intricate ceramic parts with tight tolerances and excellent surface finish. Innovacera utilizes the CIM process to produce complex components from materials like Alumina and Zirconia for medical, electronic, and consumer product applications.

Metallized Ceramic Insulators for High-Voltage Applications

Metallized ceramic insulators are critical for high-voltage equipment, combining the excellent dielectric strength of ceramics like Alumina with the solderability of metal. The metallization process creates a hermetically sealed, robust component capable of withstanding high electrical and mechanical stress, essential for vacuum interrupters, feedthroughs, and power grid components. Innovacera provides custom metallized insulators, expertly engineered for reliability in high-voltage and high-vacuum environments.

Ceramic Pistons and Plungers for High-Pressure Pumps

Ceramic pistons and plungers made from materials like Zirconia and Alumina offer superior performance in high-pressure pumps compared to their metal counterparts. Their exceptional hardness, corrosion resistance, and smooth surface finish reduce friction and wear, leading to longer service life and reduced maintenance in applications like waterjet cutting and high-pressure cleaning. Innovacera engineers high-precision ceramic plungers that provide unmatched durability and efficiency for industrial fluid handling systems.

High-Purity Alumina Ceramics (99% Al2O3)

High-purity Alumina (Al2O3) is one of the most widely used technical ceramics, valued for its excellent electrical insulation, high mechanical strength, and resistance to wear and corrosion. With purity levels of 99% and above, it is ideal for a vast range of applications, including semiconductor components, furnace tubes, insulators, and crucibles. Innovacera produces dense, high-purity alumina components, offering a reliable and cost-effective solution for high-performance industrial applications.

Silicon Nitride Bearings for Demanding Applications

Silicon Nitride (Si3N4) ceramic bearings offer significant advantages over traditional steel bearings, including higher hardness, lower density, lower friction, and superior corrosion and temperature resistance. These properties make them ideal for high-speed spindles, vacuum environments, and electric motors where they extend service life and improve performance. Innovacera’s precision silicon nitride balls and rollers are key components in hybrid and full ceramic bearings for the most demanding industries.