Markets for precision glass and ceramic components
ShapeFab manufactures precision components from technical glass and ceramics for demanding industries: semiconductor manufacturing, optics, analytical technology & life sciences, laser technology, medical technology, and the watchmaking and luxury goods industries. ISO 9001 certified. Manufacturing in Jena, Germany.
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- Glass materials
- Ceramic materials
- Technology details
- Products
Semiconductor industry
Using 5-axis machining, we enable you to produce complex geometric structures, such as free-form surfaces and lens arrays, in a reliable production environment. These can be positioned with the tightest tolerances relative to existing microstructures, such as lithographic patterns and etched features. Proven technologies ensure that sensitive structures or coatings are protected during the machining process.
Typical specifications: Fused silica, Al₂O₃, SiC. Tolerances up to ±3 µm, positional tolerances up to 5 µm, surface roughness up to Ra 8 nm.
Product examples: Vacuum clamping plates with customised channel layouts, wafer carriers and holders, process gas manifolds, component mounts for inspection systems, ceramic insulating components, frame-less lithographed sensor optics, lightweight structures
Optical components
The increasing miniaturization of complex optical systems is becoming more and more important. With our technology several manufacturing processes can be combined in a single process step. This allows 3-dimensional geometries and optically effective surfaces to be combined on one component. In this way completely new component designs are enabled, such as directly mountable and assembly-free optical components.
Typical specifications: N-BK7, Zerodur®, quartz glass. Free-form surfaces and optically active surfaces in a single clamping operation, dimensional accuracy in the micrometre range, polished to Ra 8 nm.
Product examples: Alignment components for optical assemblies, mounting plates with µm-precision fit, Monolithically integrated aspheres, lens arrays with mounting geometries, mount-free integration of free form surfaces
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- Glass materials
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Analytical Technology & Life Science
The request for mobile applications and rapid availability of test results are constantly driving the development of analytical technology and life science. A wide variety of analytical methods for liquids and gases are increasingly relying on chemically stable microfluidic systems made of glass. For this purpose, we can realize complex microstructured channel, holes and connection systems for you, through which the smallest quantities of gases or liquids can be analyzed.
Typical specifications: Microfluidic channels from 300 µm in width, 3D structures in borosilicate glass and quartz glass.
Product examples: Lab on a chip systems, microanalysis systems, microreactors, custom microscope slides.
Laser technology
Laser technologies have become significantly more important due to the rapid growth of laser applications across a wide range of industries. For example, demand for laser-based systems has risen as a result of the increasing adoption of laser technology in the automotive and electronics sectors, the growing use of lasers in healthcare, and the expanding application of laser-based material processing. This usually requires key components for beam guidance and shaping made of glass or ceramics. ShapeFab develops and manufactures customised precision parts and optical components of a wide variety of geometries within the field of laser technology.
Typical specifications: Components made of quartz glass and Zerodur with minimal thermal expansion, tolerances up to ±3 µm.
Product examples: Components for optical fibres, laser gyroscopes, mount-free integration of optical elements, mirror mounts with minimal thermal drift
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- Glass materials
- Further product examples
- Manufacturing accuracies
Medical technology
Medical devices and diagnostic systems place the highest demands on dimensional accuracy, surface quality and material purity. ShapeFab manufactures precision components from biocompatible ceramics and engineering glasses for device manufacturers, laboratory technology and diagnostics. Our 5-axis CNC machining enables the production of complex geometries even in brittle, hard materials such as zirconia and aluminium oxide – from prototypes to qualified small-batch production.
Typical specifications: Biocompatible materials (Al₂O₃, ZrO₂), tolerances up to ±3 µm, surface roughness from Ra 8 nm.
Product examples: Free-form glass components, ceramic components for surgical instruments, endoscope components, sensor housings for diagnostic devices, implant accessories, reagent carriers
Watch industry & luxury goods
Sapphire crystal is the second-hardest transparent material after diamond – scratch-resistant, chemically resistant and optically brilliant. Its machining requires specialised CNC processes and diamond tools, which ShapeFab has been mastering for years. We manufacture watch crystals, display covers and decorative components from technical glass and ceramics.
Typical specifications: Sapphire glass, quartz glass, technical ceramics. High dimensional accuracy and optical polishing with surface roughness from Ra 8 nm
Product examples: Decorative glass components, housing parts with a mirror finish