From Powder to Precision: How do we make Zirconia Beads?

davidmeng329
Sep 29
2 min read

At Stone Peak Technologies, we pride ourselves on turning high-quality zirconium oxide (ZrO₂) raw materials into precision zirconia beads used in demanding industrial, optics, and electronics applications. Let's take a tour through our process — from raw material inspection to the finished product ready for shipment.

1. Raw Material Inspection & Chemical Testing

Before any shaping begins, our incoming zirconium oxide powder (often yttria-stabilized zirconia) undergoes rigorous inspection:

Purity & composition analysis (e.g. XRD, ICP) to confirm the correct phase content and dopant levels (e.g. Y₂O₃ or other stabilizers).
Particle size distribution (PSD) measurement to ensure the powder is within spec (ultrafine, uniformly dispersed).
Physical property checks like moisture content, specific surface area (BET), flowability, and impurity levels.

This upfront control ensures that downstream steps aren’t compromised by variability in raw feedstock.

2. Molding / Shaping & Sintering

With approved raw powder in hand, Stone Peak uses one or more of the forming technologies depending on the target bead size and performance. Once “green” beads are formed, they are dried (often via controlled heating) to remove bound moisture, then sintered at high temperature (typically in the range of 1,400–1,600 °C, depending on composition and additives). The sintering densifies the beads, eliminates porosity, and locks in mechanical strength.

At Stone Peak, we optimize ramp rates, dwell times, and atmosphere control to ensure minimal defects, uniform grain growth, and proper stabilization of the tetragonal/yttria phases.

Sintering Furnace at Stone Peak Technologies' Workshop

3. Polishing

After sintering, the surface finish of the beads is crucial (especially for optical or precision applications). Through polishing, we reduce surface roughness, remove minute surface flaws, and improve sphericity in micro-scale.

Polishing Process at Stone Peak Technologies

4. Shape Selection & Sphericity Screening

Not all beads emerging from sintering and polishing meet our strict geometric standards. At the shape selection process, automated sphericity measurement identifies beads deviating from tolerance, and only beads meeting a defined sphericity spec move forward.

Sphericity Screen Machines at Stone Peak Technologies

5. Final Inspection & Physical Characterization

The selected beads must meet mechanical, dimensional, and performance specs. Key tests include:

Dimensional / size check — verifying diameters, size distribution, tolerances.
Density / porosity measurement — often via Archimedes (liquid immersion) or helium pycnometry.
Hardness / microhardness testing (e.g. Vickers)
Crush strength / compressive strength — testing how much load a bead can sustain before failure.
Wear / abrasion resistance testing — simulating service conditions to measure mass loss or surface degradation.

This inspection regime ensures that only beads meeting performance margins go to packaging.

6. Packaging & Shipping

Once approved, beads are cleaned (e.g. ultrasonic wash, degreasing) and dried. They are packaged in protective containers to prevent contamination, moisture ingress, or damage.

At Stone Peak Technologies, our high-purity zirconia beads are engineered for demanding dry and wet grinding applications, ensuring reliable performance across industries such as paints and coatings, mineral processing, battery materials, and fine ceramics.