breakthrough applications created by ceramic injection moulding technology (cim)€¦ · ·...

Breakthrough applications created by ceramic injection moulding technology (CIM)

Dipl. – Ing. Uwe Haupt

Breakthrough CIM applications

Agenda • Introduction

• Process description

• Fields of application

• Current examples

• Future possibilities

• Summary

2 © Copyright by ARBURG 11/2015

Our company

Introduction

~ 2,400 employees worldwide Consolidated turnover 2013: 480 million euros 2014: 548 million euros Export share ~60%


Introduction

We are in an excellent position worldwide

Own sales and service organisations at 32 locations in 24 countries

Trading partners in more than 50 countries


Introduction

ALLROUNDER: modular inj. moulding machines

Horizontal and vertical clamping units Clamping forces from 125 to 5,000 kN Moulded part weights from 0.001 to 2,583 g PS


Introduction

FACTS about ARBURG • More than 1000 ARBURG PIM machines sold

• ARBURG has unique expertise and experts for PIM Customer Support

• ARBURG is the only IMM manufacturer with its own PIM lab

• ARBURG has equipment for mixing, moulding, debinding and sintering

• ARBURG has equipment to analyse density, thermogravimetrical properties, metallurgy and structure

• ARBURG is for more than 25 years actively involved in PIM


Introduction

Metal- and Ceramic Injection Moulding PIM

Powder Injection Moulding

MIM Metal Injection

Moulding

Iron and Steel, Non Ferrous Alloys,

Heavy Metals

CIM Ceramic Injection

Moulding

Oxides, Nitrides, Carbides, Ferrites


At a glance

Exploiting injection moulding potential In focus: complex components with high unit volumes

Part complexity Low

Axial / Isostatic pressing

Low-pressure injection moulding,

Slip casting

1000 P

rodu

ctio

n (th

ousa

nd u

nits

)

100

10

1 Medium High

Ceramic injection moulding

(CIM)


At a glance

Exploiting injection moulding potential + • Volume production – high degree of

automation possible • Production can be adapted quickly • Complex geometry and free-form

surfaces possible • Near netshape contour components

with high dimensional stability and surface quality

• Homogeneous component density • Almost wasteless production • Large choice of materials

- • Expensive powders • Multi-stage manufacturing process


Process sequence overview

Multi-stage: the manufacturing process

Feedstock preparation

Injection moulding

Debinding Sintering

Secondary operation Regrind


Wide range of injectable feedstocks available

Reliance on comprehensive support

Debinding unit Pre-mixer

Mixing unit

Sintering furnace Injection moulding machine

Robotic system

Mould Granulating unit

Temperature control unit

At a glance

Feedstock preparation

Injection moulding

Debinding Sintering

Powder Feedstock Green

compact Brown

compact Finished part

Binder

Process sequence – from component point-of-view Process sequence – from production process point-of-view Process sequence – possible secondary processes Expert consulting throughout the process chain

Grinder / jaw crusher Grinding machine

Paint shop ...

Breaking sprues

Secondary operation

Unique ARBURG service range


Typical values for powder injection moulding

Multi-stage: the manufacturing process

Dimensions Length Diameter Wall thickness Bores Edge radius

[mm] < 100 < 50 .

0.5 – 12

> 0.1 > 0.1

Tolerances Normal Best

[%] +/- 0.3 +/- 0.1

Volumes [cm³] 0.05 - 150

Relative density Typical [%] > 94 .

Surface quality [Ra] 0.4 – 1.6



Reasons to choose Ceramic More than 40 companies in Europe are making ceramic products using injection moulding technique

Sources: Internet, Ceramtec

Maxon Ceramics SPT Roth

Complexity Miniaturisation

RSG Solingen

Flexibility Hardness

MKS GmbH Maxon Motor



High precision Ceramic Ferrule • Flexible connection for

glass fiber wiring,

• Zero-loss data transfer

total diam. 0,167 mm length of core 25 mm tolerance +/- 0,001 mm



Grinding disk for industrial coffee machines Problem: • Multiple Processes required

- casting, machining, hardening and grinding

• Long lead time

• High cost

• Deformation during hardening led to low yield


Grinding disk for industrial coffee machines Solution: metal replacement by CIM part • Higher lifecycle because of hardness

• Nickel free

• Better grinding properties

• Chemical resistant




Puncture Plate for Coffee Capsules • ATZ



Scalpel ZrO2 „X-Ray invisible“, Sharp



Tweezers ZrO2 „elastic“



Punch rivet Al2O3 Dimension / weight height 4 mm / app. 0,2 g


Cell Phone Housing ZrO2, coloured, polished



CeramCool® Heat sinks (alumina / aluminum nitride) for high power LED-systems

Source: Ceramtec




Watches ZrO2

• Parts: Watch housing, Bezel or Wristband

• Coloured or natural Zirconia

Source: Internet



Air conditioning control panel

• Matching surface feel / turning moment to higher mass

• Roundness at different section thicknesses

• Different surfaces (polished / matte) within one part

• Joining technologies of different parts

Source: Oechsler

Air condition control panel



Central control unit • Matching surface feel / turning

moment to higher mass

• Roundness at complex inner contour (rotation swivel)

• Different surfaces (polished / matte) within one part

• Meeting EMV-protection standards (circle cover)

• Polishing extreme concave surfaces

Source: Oechsler

Central control unit

Rotation swivel

Circle cover Cover



Gear selection lever • Large free-form surface high-

gloss polished

• Crash test and malfunction requirements

• Deformation crucial due to one-sided open geometry

• Tolerance requirement very high (< 0,1 mm at approx. 100 mm) referring to size and free-form geometry of the part

Gear selection lever

Source: Oechsler 26 © Copyright by ARBURG 11/2015


Probe head Si3N4



Probe head ZTA 20 Dimension / weight D 1,0 – 7,4 mm / ~ 0,04 g



Implant ZrO2 • Good attachment of cells

• Biocompatible

Source: TAV medical


Implant ZrO2


Quelle: ZDA Quelle: ZDA


Abutment ZrO2


Quelle: TAV medical Quelle: TAV medical


Future Applications

Gas Internal Pressure Moulding at MIM and CIM • Weight reduction and reduced process times


Future Applications

Lost Core Process • 1. Mould lost core (POM)


Future Applications

Lost Core Process • 2. Overmould lost core with Feedstock


Future Applications

Movable Link, assembly moulded


Future Applications

Two Component Cup, Porcelain


Infomaterial

ARBURG PIM-Website (german / english)

PIM-Newsletter Subscription

Download Section


Infomaterial

Expertenkreis Keramikspritzguss • http://www.keramikspritzguss.eu/

ARBURG PIM-Newsletter • http://www.arburg.com/de/leistungss

pektrum/spritzgiessen/verfahren/pulver-spritzgiessen-pim/pim-newsletter-subscribe


http://www.keramikspritzguss.eu/


Tel.: +49 (0) 7446 33-0 Fax: +49 (0) 7446 33-3365 E-mail: [email protected] www.arburg.com

ARBURG GmbH + Co KG Arthur-Hehl-Strasse D-72290 Lossburg

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