The mass production of components with dimensions in the micron and sub-micron range is anticipated to be one of the leading technology areas for the present century and to be of high market potential. Micro metal injection molding (μMIM) has the potential to be an important contributor to this industry as it can produce precise metallic microstructures in large quantities at a relatively low production cost. The μMIM process is a miniaturization of metal injection molding (MIM) methods. The process comprises of four main steps: mixing, injection molding, debinding and sintering. A metallic powder is mixed with a binder system to form the feedstock. The feedstock is then
injection molded into the required shape and the binder removed via thermal or other means. The final microstructures are obtained by sintering the remaining powder in a controlled
environment. In this work, the dimensional variation of the microstructures, in particular the warpage, roughness and volume variation, at each stage of the μMIM process was quantified and compared. The results of a preliminary study of the sensitivity of warpage of the microstructures to the
packing pressure are also reported.Singapore-MIT Alliance (SMA
