Feature article: PIM International, Vol.2 No. 1 March 2008, pages 37-42, 3403 words

Author: Dr.-Ing. Frank Petzoldt, Fraunhofer IFAM, Germany

Deputy Director, Fraunhofer IFAM, Wiener Str. 12, 28359 Bremen, Germany

Introduction

In this specially commissioned feature for Powder Injection Moulding International, Dr Frank Petzoldt takes a closer look at micro-PIM technology. Potential markets and applications are assessed as many companies are already starting to turn theory into practice in this exciting sector of the PIM industry

During the last ten years powder injection moulding (PIM) has become a reliable production technology for complex shaped metallic and ceramic parts. Today, the PIM industry is on a good growth track world-wide. In such a positive economic environment the question should be asked: where are the next opportunities and challenges for PIM? There are definitely some answers with a completely different focus on this simple question. First of all, market expansion should be mentioned as a driver for further technological development. Winning parts from other manufacturing technologies such as investment casting and machining is possible if tolerances and part quality are improved continuously at a competitive price level. A second answer is the trend to produce bigger components by PIM with a weight of more than 200g. This is a great challenge for the powder producers to offer fine powders on a reasonable price level. A third answer is to adapt a manufacturing technology like PIM to market needs in completely new branches like micro system technology (MST) or in the field of biosensors.

The trend towards miniaturisation of products and systems is almost omnipresent. Structural and functional components in complex systems are becoming smaller and smaller. The integration of an increasing number of functions can be achieved by the use of advanced materials with suitable physical properties but also by miniaturised geometrical features. Therefore highly efficient and reliable methods for the mass production of micro components or micro structured components need to be developed. The definition of what is 'micro' is not standardised or clearly defined yet. One possible measure is a lateral part dimension of less than 1mm and structural features of less than 100µm.

Another definition could be a part weight in the range of......

Further sections of this article include:

- Market potential for micro- PIM
- Micro-PIM today
- Some key industrial players in micro-PIM
- Research activities
- Outlook

Figures and Tables:

Fig. 1 Market opportunities for micro-PIM

Fig. 2 The FAMOS micro reaction toolkit – hexagonal fluidic modules on a functionalised baseplate (Fraunhofer IKTS)

Fig. 3 Opened reaction module with adjustable mixing unit (Fraunhofer IKTS)

Fig. 4 Micro-MIM 17-4PH gear (Forschungszentrum Karlsruhe, Germany)

Fig. 5 Ceramic gear parts (Forschungszentrum Karlsruhe, Germany)

Fig. 6 Vortex mixer 316L stainless steel (Fraunhofer IFAM)

Fig. 7 Miniature parts out of 316L (Fraunhofer IFAM in co-operation with Scholz GmbH, Kronach, Germany)

Fig. 8 Positioning sensor made by magnetic / non-magnetic 2-component micro MIM (Fraunhofer IFAM)

Fig.9 Micro gears made from two different ceramics (Forschungszentrum Karlsruhe, Germany)

Fig.10 SIGMA calculation of temperature distribution during injection moulding of a micro part

Fig. 11 Micro-PIM market and technology development