Feature article: PIM International, Vol.1 No. 2 June 2007, pages 33-36, 2071 words

Author: Professor Randall M. German, San Diego State University, USA

College of Engineering, San Diego State University, 5500 Campanile Drive, San Diego, CA 92182-1326, USA

Introduction

Sustained research and development activity is critical to the future prosperity of the global PIM industry. Professor Randall German compares past and current levels of activity and identifies where the focus of attention now lies.

The overall powder injection moulding industry has been profitable for about 15 years. The progression into financially viability was built on research and development efforts performed during the 1970s and 1980s. Like with other technologies, R&D is a leading indicator for commercial success. By capturing the current PIM R&D effort we can project future commercial trends. In this analysis, shifts in geography, materials, and component sizes become evident. In Asia, the R&D effort is focused on developing standard materials, designs, and applications. In the USA and Europe, much of the R&D effort is on titanium and tungsten, smaller devices, computer simulations to improve predictive capabilities, and medical applications. Currently, global PIM R&D relies on about 225 researchers using over $40 million in installed equipment. For 2007, the PIM R&D community plans to spend up to $19 million on new equipment. About 40% of that will be at universities, 35% at independent research operations, and 25% at industry.

Profiling R&D trends

Powder injection moulding (PIM) is following a path similar to that taken by traditional powder metallurgy. Both showed slow initial growth followed by a spurt of rapid growth with ensuing high profits. As scientific principles were discovered and applied by the early 1990s, PIM became stable, predictable, and profitable. More recently sales growth has slowed since gains anticipated in large markets, such as automotive, have been slow to mature, while the commercial competition has become global. It seems typical to both ....

Further sections of this article include:

- Profiling R&D trends
- Metrics of R&D growth
- New directions for PIM
- Conclusions

Figures and Tables:

Fig. 1 A scanning electron micrograph of the high pressure water atomized stainless steel powder. It is a lower cost option designed for PIM applications

Fig. 2 An example of a poor packing powder that is used in PIM because of its low cost, but this titanium powder is difficult to mould because of the particle shape

Fig. 3 A polished cross-section through a high pressure water atomised stainless steel powder showing how the particles are dense

Fig. 4 A picture of a model high packing density particle with an elongated shape which would be ideal for moulding

Fig. 5 A typical hard shell chocolate candy that has the desirable aspect ratio sought for PIM powders

Fig. 6 Cracks in sintered PIM components resulting from improper feedstock design, showing a cell phone vibrator weight and an alumina jetting plate

Fig. 7 Birdshot is one of the highest production items by PIM. The feedstock is self-mixed for this application

Fig. 8 A high volume cell phone component which relies on self-mixed feedstock

Fig. 9 Small orthodontic components showing the size range that appears to be the growth direction for PIM

Fig. 10 An example of a small medical biopsy component fabricated by PIM with features in the 100 micrometer size range (this device is 8 mm in length and 0.1 mm thick)

Table 1 Weight Percent Binder for 60 vol. % Solids Loading with Different Powders

Table 2 Examples of PIM Stainless Steel Powders

Table 3 Attributes Associated with a PIM Powder

Table 4 Key attributes for PIM binders