The combination of generative and algorithmic design with Additive Manufacturing is opening up a new world of opportunity for ceramics. Whilst Ceramic Injection Moulding has, until now, been the manufacturing process that offered the greatest level of design freedom for industrial production, ceramic AM now brings a level of freedom to produce complex structures that go far beyond what can be moulded. Prof Alberto Ortona, from the Hybrid Materials Laboratory at University of Applied Sciences and Arts of Southern Switzerland (SUPSI), explores ceramic Binder Jetting, the opportunities that it presents, and its current limitations.
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The ability of Metal Injection Molding to efficiently manufacture complex stainless steel components to net shape has enabled it to become a go-to technology for sectors such as watchmaking, luxury goods and medical devices. However, the challenge of meeting the growing demand for nickel-free stainless steels presents a number of challenges for MIM producers. In this article, Pierre Girin and Jean-Claude Bihr, from France’s Alliance MIM, review these challenges and share insight into the processing of a material class that holds great promise for the industry.
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A Special Interest Seminar in the programme of the virtual Euro PM2021 conference, organised by the European Powder Metallurgy Association (EPMA) and held October 18-22, 2021, focused on developments aimed at enhancing the sustainability of production by Metal Injection Moulding. This seminar comprised three presentations from representatives of different points in the MIM process chain.
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In recent years there has been a surge in interest in sinter-based metal Additive Manufacturing, with many of these technologies adapting the materials used in Metal Injection Moulding. Whilst Binder Jetting (BJT) and Material Extrusion (MEX) processes lead the field in terms of market penetration, sometimes something radically different comes along. This is certainly the case with Germany’s Headmade Materials, whose Cold Metal Fusion (CMF) AM process takes a completely new approach. Dr Georg Schlieper visited the company and reports for PIM International on the company and its technology.
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SSI Sintered Specialties, LLC can trace its roots back to the earliest days of Powder Metallurgy in the US. True to its name, that company has over the decades found success through specialisation, in particular stainless steel PM products. This is a theme that continues today, with the company now expanding its horizons through the development of large Metal Injection Molding parts using innovative feedstock technology, and the adoption of metal Binder Jetting. Bernard North visited the company on behalf of PIM International and reports on its plans to remain at the forefront of metal powder based parts production.
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A technical session, comprising three papers, at the Euro PM2021 Virtual Congress, organised by the European Powder Metallurgy Association (EPMA) and held from October 18–22, 2021, assessed various aspects of the formulation and preparation of feedstocks for Metal Injection Moulding. Dr David Whittaker reports on three papers that addressed solvent debinding efficiency, strategies for enhancing the debinding of polyacetal (POM) feedstocks, and, lastly, an analytical method for enhancing the understanding of the homogeneity of MIM feedstocks and green parts.
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In March 2007, the very first issue of PIM International featured a review of Metal Injection Molding in Asia. China’s MIM industry was estimated as having around twenty MIM firms, many modest in size and of limited capability, with Taiwan accounting for another fifteen. Fast forward less than fifteen years, and Greater China now accounts for half of global Metal Injection Molding production, is a leader in MIM-grade powder production, and is home to a host of production equipment manufacturers. Industry consultant Dr Chiou Yau Hung (Dr Q) assesses just what happened to drive this success: good fortune, good strategy, or a slice of both?
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Type 420 martensitic stainless steel covers a wide carbon range of 0.15% to 0.45%. Demand for this material from the 3C, automotive, biomedical and aerospace industries has been increasing thanks to its combination of moderate corrosion resistance, high hardness, and good tensile properties. In this study, Shu-Hsu Hsieh, Dr Chung-Huei Chueh, and I-Shiuan Chen, from Chenming Electronic Technology Corp. (UNEEC), Taiwan, investigated Nb-alloyed 420 produced using BASF SE’s Catamold 420 W feedstock. Decarburisation was examined in samples processed in both a graphite furnace and a molybdenum lined furnace. Microstructure, phase and hardness variations from the sintered state to each specific stage in heat treatment were also explored. Additionally, the influence of niobium on the formation of intergranular compounds, carbides, and carbonitrides was also assessed in each heat treatment stage for comparison.
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The ability to innovate is the cornerstone of the successful evolution of technology companies. Jiangsu Gian Technology Co., Ltd., China’s largest Metal Injection Moulding company, has always followed such a philosophy. Dr Chiou Yau Hung (Dr Q) visited the company on behalf of PIM International and spoke with Junwen Wu, the company’s vice president, about how innovation, from materials development to the use of Artifical Intelligence for advanced quality management, has become the driving force behind the company’s success.
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Binder Jetting – at once the new kid on the block yet one of the industry’s earliest processes – holds the promise of taking metal Additive Manufacturing into the territory of true high-volume production. Yet progress towards this goal appears to be struggling, with machine sales lower than many hoped and two new ‘big players’ appearing to be holding back on full commercialisation. In this report, Joseph Kowen considers the development of this industry to date, the obstacles facing its growth, and, of course, the recent announcement of two of Binder Jetting’s biggest rivals coming together in the most unexpected acquisition.
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