Andreas Ruh

Recent developments in micro ceramic injection molding

Abstract Effective material application and miniaturization, both indispensable to modern product development and production, demand enhanced manufacturing processes suitable for both micro devices and economic series production. For micro parts made of polymeric materials, micro injection molding represents such a method and has already reached an industrially viable status. For manufacturing of ceramic products micro powder injection molding is a promising option because it combines the possibility of large-scale series production with a wide range of materials, thus possessing a considerable economic potential. An enhanced variant, micro two-component injection molding enables, for example, the fabrication of micro components consisting of two ceramic materials with different physical properties and, furthermore, significantly minimizes mounting expenditure.

Micro PIM moves into the zone of industrial possibility

Increasing demand for ever-smaller devices presents challenges for materials science. German researchers are looking at the possibilities of micro powder injection moulding, and how to match the process to the needs of large-scale industrial production…

Manufacturing of High-Grade Micro Components by Powder Injection Molding

Powder injection molding (MicroPIM) has a considerable potential for the production of high-value metal and ceramic micro components. This does not only apply to technical aspects but, due to the deployability of mass production, also to economic ones. The current status can be summed up by the following key data: latest trials revealed smallest struc-tural details in the 10µm range or lower. Theoretical densities of up to 99% were achieved depend-ing on the particular powder applied. Typical materials processed are metals (Fe, Cu, 316L, 17-4PH, W and W-alloys etc.) or ceramics (aluminum/zirconium oxide etc.). Best surface qualities were obtained with ultrafine or even nano-doped ceramic powders. Another major line of development is multi-component or assembly injection molding. These proc-esses do not only reduce assembly expenditure, but also allow for the use of new functional material combinations. Interesting examples are ceramic micro heating elements or gear wheel/shaft samples which can be performed as fixed or movable combinations. Micro inmold-labelling using PIM feed-stocks offers further promising opportunities.

Micro systems need a boost in manufacturing methodologies

While macroscopic powder injection moulding is drawing the attention of mass manufacturing and winning plaudits for its high process and economic efficiency, its micro variant still faces challenges…