--- title: "In conversation with Bosch Advanced Ceramics" url: https://www.voxelmatters.com/in-conversation-with-bosch-advanced-ceramics/ date: 2025-09-01 modified: 2025-09-01 lang: en author: "Tess Boissonneault" description: "With over a decade of experience working with technical ceramics, Bosch Advanced Ceramics (BAC), a unit of Bosch Business Innovations, has become a trusted contract manufacturer in the still niche..." categories: - "3D Printing Service Providers" - "Ceramic Additive Manufacturing" - "Ceramics" - "Executive Interviews" - "Sponsored" tags: - "Featured" image: https://www.voxelmatters.com/wp-content/uploads/2025/09/Fotoshooting_2022_18_apic-640x427.jpg word_count: 2232 --- # In conversation with Bosch Advanced Ceramics With over a decade of experience working with technical ceramics, [Bosch Advanced Ceramics (BAC), a unit of Bosch Business Innovations](https://www.voxelmatters.directory/company/bosch-advanced-ceramics/), has become a trusted contract manufacturer in the still niche but maturing ceramics AM market. The company, which operates a cutting-edge production facility in Immenstadt, Germany, has successfully worked with customers from the semiconductor, medical and aerospace industries—among others—not only in the production of high-quality ceramic AM parts, but also through consultancy services. This holistic approach to contract manufacturing means that BAC can enable its clients to really maximize the benefits of ceramic AM and push the technology to new limits. We recently had the opportunity to speak with Nikolai Sauer, the CTO of Bosch Advanced Ceramics, whose own experience with technical ceramics and additive technologies has played an important role in the company’s increasingly influential position. In our interview, Sauer tells us all about BAC’s current capabilities and activities in ceramic AM, market challenges that the company (and industry at large) are tackling and how he envisions the future of ceramic AM. ## A brief introduction Nikolai Sauer is a Bosch veteran, having worked at [the company](https://www.voxelmatters.com/bosch-advanced-ceramics-3d-prints-1400-medtech-components-in-a-single-batch/) since 2008, when he took on an apprenticeship as a mechatronics technician. Even later, when Sauer pursued a degree in industrial engineering with a focus on mechanical engineering, he stayed involved at Bosch through a series of internships. It was in his time as an intern that he first learned about technical ceramics. “I also had the opportunity to work with the first 3D printer acquired for ceramic applications at that time,” he tells us. “I dedicated significant time to understanding this technology and contributed to its fundamental process development. Upon graduating, I was offered a position as the first development engineer solely focused on 3D printing of ceramics. In this role, I managed initial customer projects and helped to industrialize our processes. As customer demand grew, I had the chance to expand our machinery, integrate new technologies, and build a dedicated team for additive manufacturing of ceramics.” More recently, Sauer and his team at BAC have been focused on advancing the industrialization of ceramic AM processes as well as expanding the company’s material and technology portfolio. In his current role of CTO, a leadership role he has held since 2023, Sauer is responsible for overseeing all technical aspects of the contract manufacturer, including production, development, quality assurance and project management. This scope covers BAC’s sophisticated production facility, where the team uses two ceramic AM processes in its manufacturing: Lithoz’s Lithography-based Ceramic Manufacturing (LCM) and 3DCeram’s SLA. “Our current machine park includes several 3D printers, complemented by post-processing machines such as our high-temperature furnaces for ceramic sintering,” he elaborates. “This comprehensive setup allows us to specialize in the reliable series production of technical ceramic components according to client specifications.” Sauer does also note that BAC has two other technologies in its development phase: “Our technical team constantly monitors new developments and emerging technologies in ceramic AM. We evaluate what could be suitable for future series production, always looking for the most efficient solutions for our clients.” ![](https://www.voxelmatters.com/wp-content/uploads/2025/09/Fotoshooting_2022_13.2_apic-scaled.jpg)Credit: Martin Stollberg. ## A myriad of applications Presently, [Bosch Advanced Ceramics manufactures a wide range](https://www.voxelmatters.com/bosch-invests-e6-million-in-nuremberg-3d-printing-to-date/) of components for its clients, including micro-components for medical devices and larger parts for the semiconductor industry. This means that the company has a deep understanding of ceramic AM’s versatility, particularly when it comes to scale. Sauer explains: “To give you an idea of our current capabilities: the smallest part we’ve produced so far is an insulation sleeve with an outer diameter of just 1.3 mm and a wall thickness of only 90 µm. On the other end of the spectrum, we manufacture larger components such as ring blades for wafer handling, with diameters of up to 250 mm. The maximum size ultimately depends on the machine, but the market is evolving rapidly, and we continuously monitor new developments to expand our possibilities. For us, size isn't the primary differentiator; it's about the application challenge.” Indeed, what is more interesting to BAC when working with clients is helping them to understand when ceramic AM is really the right choice. Often, it comes down to three factors that a component requires: Extreme environment suitability: Thanks to the inherent properties of technical ceramics (high temperature, chemical resistance, wear resistance). Complex geometries: Enabling optimized designs or the integration of multiple functions into a single part, which isn't feasible with conventional manufacturing. Rapid prototyping or small to medium series production: Where traditional tooling costs would be prohibitive. “Our focus is always on supporting our clients from a very early stage in the project,” he adds. “We work together to maximize the benefits of additive manufacturing, for instance, by consolidating entire assemblies into one complex printed part. This immense design freedom, combined with the superior properties of technical ceramics, offers significant advantages across all part sizes.” Sauer highlights a use case that showcases how these factors are well paired with ceramic AM. “Among the various applications we've manufactured, the gas injector stands out as a prime example of ceramic additive manufacturing's innovative potential,” he says. “This component truly pushes the boundaries of what's possible in terms of design and performance. Its specifications are highly challenging: it combines two traditionally separate components into a single, streamlined design; features a 12mm diameter flange with three 6mm diameter channels; and, most remarkably, a 9mm diameter honeycomb nozzle with ultra-thin 0.2mm wall thickness, all manufactured from alumina at a height of 42mm.” This particular case study is a perfect example of how ceramic AM can, more than any other technical ceramic manufacturing process, create highly complex geometries with internal structures and thin walls. Presently, BAC is manufacturing this component in medium-sized volumes. “The development process for this gas injector was also highly collaborative,” Sauer emphasizes. “We worked in very close partnership with the client from the initial design phase through to production. This close cooperation was essential to meet the stringent requirements for performance, cleanliness and material properties necessary for its intended use in demanding industries like semiconductor, aerospace or energy.” ![In conversation with Bosch Advanced Ceramics. Nikolai Sauer tells us all about its production capability and the grand picture for ceramic AM.](https://www.voxelmatters.com/wp-content/uploads/2025/09/Fotoshooting_2022_6_apic-scaled.jpg)Credit: Martin Stollberg. ## The industries warming to ceramic AM Bosch Advanced Ceramics’ [experience manufacturing ceramic AM components](https://www.voxelmatters.com/bosch-advanced-ceramics-is-now-part-bosch-business-innovations/) has given Sauer and his team unique insights in the broader ceramic AM market, including trends and challenges. Considering ceramic AM is a technology that is still considered by many to be emerging, we were curious to ask where the strongest adoption interest was coming from and which industries could seek to benefit most from ceramic AM’s capabilities. “We're seeing significant traction and rapid adoption of ceramic AM components primarily in industries that already rely heavily on the unique properties of advanced ceramics,” Sauer explains. “For instance, in the semiconductor industry, the demand for extreme precision, high purity and temperature stability is paramount. Ceramic AM allows for complex geometries like intricate fluidic channels or specialized wafer handling tools that are often impossible or too costly to produce conventionally. “Similarly, the medical devices sector is highly receptive, driven by needs for biocompatibility, wear resistance, and the ability to create highly customized or intricate designs for implants or surgical instruments.” (On this front, Bosch Advanced Ceramics recently revealed it was producing 1,400 ceramic insulating sleeves for laparoscopic tools in a single build, demonstrating the potential for scalable production volumes for the medical sector.) “Beyond these, industries like aerospace, which traditionally focused on metals, are increasingly turning to ceramic AM. This shift is driven by their push for lightweighting, high-temperature resistance and enhanced performance in harsh environments, making ceramic components ideal for sensors, nozzles or thermal protection. The automotive sector, particularly in high-performance and e-mobility applications, also benefits from ceramics' electrical insulation, thermal management, and wear resistance for components in sensors, batteries, or specialized engine parts.” Where the biggest untapped potential lies, according to Sauer, comes from industries that are facing an increasing need for parts that can withstand extreme operating conditions as well as those exploring new product designs that are difficult—if not impossible—to achieve using more conventional materials and production methods. “This often involves sectors where increased demands, such as higher temperatures, more aggressive chemicals or stricter performance requirements, are forcing a re-evaluation of materials,” he explains. “We're actively engaging with areas like renewable energy, focusing on components for hydrogen production and next-gen battery systems where conventional materials are reaching their limits. “We also see strong potential in chemical processing for pumps, valves or reactors in highly corrosive or abrasive environments, and in advanced metrology or precision instrumentation where dimensional stability and extremely low thermal expansion are critical. Our mission is to inspire these industries on how ceramic AM can unlock entirely new design possibilities and performance levels, ultimately replacing conventional, often less optimal, solutions.” ![In conversation with Bosch Advanced Ceramics. Nikolai Sauer tells us all about its production capability and the grand picture for ceramic AM.](https://www.voxelmatters.com/wp-content/uploads/2025/09/Fotoshooting_2022_16_apic-scaled.jpg)Credit: Martin Stollberg. ## Challenges to overcome The contract manufacturer’s position in the market has also given it a unique perspective on the challenges still facing ceramic AM technologies. Sauer cites awareness as one of the major hurdles to overcome: “Many decision-makers and engineers are simply not fully aware of its capabilities or how to best leverage them for their specific applications. This lack of awareness directly impacts the ability to build customer trust in ceramic AM as a reliable, high-quality manufacturing method for critical applications.” Cost is another important consideration—a challenge that is actually very tied to the lack-of-awareness challenge. “While ceramic AM offers unique advantages, the direct per-part cost can sometimes appear as an initial hurdle,” he continues. “This often ties into the broader challenge of competing with established manufacturing processes that benefit from long-optimized supply chains. “However, we consistently encourage our clients to take a comprehensive look at their project's total cost of ownership (TCO). Even if the immediate cost per part might be higher, the inherent advantages of an AM-produced component can lead to substantial long-term savings. For instance, a lightweight design could significantly reduce energy consumption, or a more durable part could extend product lifespan, ultimately resulting in a lower TCO.” Fortunately, Sauer and his team are taking proactive steps to overcome these challenges. For example, Bosch Advanced Ceramics invests significantly in partnerships and education, always encouraging collaborative projects and knowledge sharing. “We provide proof-of-concept demonstrations and support functional testing, thereby building confidence in the technology and the quality of its output,” he says. “Regarding cost and competition, our strategy focuses on automation throughout the process to reduce the cost per part for our customers. Crucially, we also actively help clients identify suitable projects where ceramic AM's unique advantages clearly outweigh conventional approaches, thus highlighting its true value proposition.” BAC also has a vested interest in enhancing the robustness of the ceramic AM process to unlock reliable, repeatable series production. On this front, Sauer says: “For process stability and scalability, we strive to understand and control every aspect of our production process, from material preparation to sophisticated post-processing, ensuring consistent quality and reproducibility.” ![](https://www.voxelmatters.com/wp-content/uploads/2025/09/WhatsApp-Image-2025-08-31-at-23.16.36-scaled.jpeg)Credit: Martin Stollberg. ## The future of ceramic AM at Bosch Advanced Ceramics Looking to the future, BAC has several focus areas it is aiming to further develop, from greater automation and more material options to larger components and process chain traceability. One of its key focus areas at the moment—which encompasses some of the aforementioned challenges and development areas—is scalability. “At BAC, our primary focus in development currently revolves around ‘scalability,’” Sauer tells us. “To achieve this, we are actively exploring cost reduction opportunities both independently and in collaboration with our partners, aiming to broaden the application of additive manufacturing in ceramics. A significant lever in this process is the automation of individual steps in production. Additionally, our suppliers play a vital role in this journey, as they must work intensively to reduce the costs of materials and printers, which is essential for bringing the entire industry closer to series production across a wider range of applications.” On the topic of traceability, he adds: “Additive manufacturing offers us unique advantages in this regard, enabling us to provide traceability down to the individual component level and even back to the raw materials. This was previously challenging and expensive with conventional technologies.” BAC’s goals of advancing industrialization of ceramic AM align perfectly with those of the broader industry. And unsurprisingly, the company, like us, has high hopes for the future of ceramic AM and sees the technology as a solution to emerging manufacturing problems associated with more traditional materials and processes. “The future of ceramic additive manufacturing looks exceptionally promising,” Sauer says. “As demand continues to grow across various applications, the technical requirements for materials are becoming increasingly stringent. Traditional materials may no longer meet these evolving needs, which positions technical ceramics as a key material for enabling our customers to push the boundaries of what is possible. “The core strength of additive manufacturing lies in its ability to enable designs impossible with conventional methods. This opens up entirely new possibilities across industries,” he concludes. “As engineers and designers increasingly embrace additive thinking, we anticipate a surge of innovative ideas and applications that could fundamentally transform various industries. In summary, while the path forward may be challenging, the untapped potential for ceramic AM applications is vast, and we are excited to explore the possibilities that lie ahead.” This article was originally published in VoxelMatters’ VM Focus Ceramic AM eBook. Read or download the full eBook for free [at this link](https://www.voxelmatters.com/voxelmatters-ceramic-am-focus-2025-ebook/).