Projects | INNOVACERA

Pyrolytic Boron Nitride (PBN) Ceramics

Pyrolytic Boron Nitride (PBN) Ceramics are an advanced form of Boron Nitride produced by Chemical Vapor Deposition (CVD), resulting in a material that is near-theoretically dense (zero porosity) and highly pure (>99.99%). PBN’s anisotropic structure provides exceptional thermal stability, extremely low outgassing, and excellent non-wetting properties. It is the material of choice for crucibles, heaters, and substrates in ultra-high purity, high-vacuum, and high-temperature applications, particularly in Molecular Beam Epitaxy (MBE) and MOCVD processes for semiconductor crystal growth. INNOVACERA supplies custom-fabricated Pyrolytic Boron Nitride (PBN) components, including crucibles and resistance heaters, ensuring ultra-high purity and consistency, which are critical for the demanding material synthesis processes in the compound semiconductor industry.

Ceramic Setter Plate

Ceramic Setter Plates are high-temperature, flat structural components used as carriers or support bases for parts during demanding thermal processes such as sintering, brazing, and heat treatment. They are essential in industries like Powder Metallurgy (MIM), advanced ceramics manufacturing, and electronics (LTCC/HTCC). Materials like Alumina (Al2O3), Zirconia (ZrO2), or Boron Nitride (BN) are chosen based on the required temperature, chemical inertness, and load-bearing characteristics. A quality setter plate prevents warping, ensures dimensional stability, and minimizes contamination of the parts being processed. INNOVACERA supplies precision-machined Ceramic Setter Plates and custom setters for MIM parts, ensuring excellent flatness and thermal shock resistance. Our advanced setter materials contribute directly to the high quality and yield of final sintered components in various high-volume production cycles.

Beryllium Oxide Ceramics

Beryllium Oxide (BeO) Ceramics stand out as a ceramic material with exceptionally high thermal conductivity, often comparable to metals, while retaining excellent electrical insulation properties. This combination makes BeO indispensable for applications in high-power microelectronics, laser components, and military/aerospace systems that require rapid and efficient heat extraction from active components. Despite handling challenges due to its toxic dust form, BeO is unmatched in specific high-frequency and high-power density applications. INNOVACERA offers custom-machined Beryllium Oxide Ceramic parts, including heat sinks and substrates, ensuring a superior thermal path for critical devices. We strictly adhere to safety protocols during the entire manufacturing process to deliver high-performance BeO components to clients in specialized high-tech sectors.

Analytical Instruments Components

Advanced ceramic materials are fundamental to the precision and reliability of modern Analytical Instruments, including mass spectrometers, gas chromatographs, and electron microscopes. Components like ceramic insulators, high vacuum feedthroughs, filter plates, and precision pump parts are essential, providing chemical inertness, extreme temperature resistance, and ultra-high vacuum compatibility that traditional materials cannot match. Ceramics ensure minimal contamination and maintain the dimensional stability required for highly sensitive measurements. INNOVACERA designs and manufactures a wide range of specialized ceramic-to-metal assemblies and pure ceramic components, such as orifice plates and resistor cores, which significantly enhance the performance and operational life of complex analytical and scientific equipment across research, medical, and industrial laboratories.

Alumina Ceramic Heater

Alumina Ceramic Heaters (MCH Heaters) leverage the excellent thermal properties and electrical insulation of Alumina to provide rapid, highly efficient, and localized heating in a compact form factor. These heaters feature an embedded refractory metal heating element co-fired with the ceramic, resulting in fast heat-up times, superior temperature uniformity, and high-temperature stability. They are widely used in critical applications like mass spectrometry, soldering irons, oxygen sensors, and pellet stoves, replacing traditional metal heating elements. INNOVACERA specializes in designing and manufacturing customized Alumina Ceramic Heaters with integrated temperature sensing capabilities and precise resistance values, ensuring high performance, long life, and energy efficiency for both industrial and consumer heating systems.

Ceramic Components for Oil and Gas Exploration

The oil and gas industry presents extreme environments of high pressure, high temperature, and corrosive chemicals. Advanced ceramics like Silicon Nitride and Zirconia excel in these conditions, offering superior wear and corrosion resistance for components in downhole tools, valves, and sensors. Innovacera provides robust ceramic solutions that enhance the reliability and lifespan of critical equipment used in exploration and production, reducing downtime and operational costs.

Alumina Ceramic Tubes for High-Temperature Furnaces

High-purity alumina ceramic tubes are a staple in high-temperature furnace applications due to their excellent thermal stability, high dielectric strength, and resistance to chemical attack. They are commonly used as protection tubes for thermocouples, insulators, and process tubes in heat treatment, melting, and diffusion furnaces operating at temperatures up to 1700°C. Innovacera supplies a wide variety of standard and custom-sized alumina tubes to meet the rigorous demands of industrial and laboratory furnaces.

Metallization of Ceramics for Electronic Packaging

Ceramic metallization is the process of applying a thin, adherent metal layer onto a ceramic surface, enabling it to be brazed to other components. This is fundamental for electronic packaging, creating hermetic seals for sensors, RF packages, and power modules that require both electrical conductivity and insulation. Innovacera offers various metallization services, including Mo-Mn and thick-film techniques, to create reliable, high-performance ceramic-to-metal assemblies for the electronics industry.

Advanced Ceramics for 5G and Telecommunications

The rollout of 5G and advanced telecommunications requires materials with excellent high-frequency performance, low signal loss, and stable thermal properties. Advanced ceramics like Alumina, Aluminum Nitride, and Beryllia are ideal for manufacturing filters, substrates, and packages for RF and microwave components. Innovacera develops specialized ceramic materials and metallized components that enable higher performance and miniaturization in next-generation communication infrastructure.

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.