Piotter, V.

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KIT – Universität des Landes Baden-Württemberg undnationales Forschungszentrum in der Helmholtz-GemeinschaftINSTITUTE FOR APPLIED MATERIALS  - MATERIALS PROCESS TECHNOLOGY  (IAM – WPT)www.kit.eduNano- and Micro Injection Mouldingof polymer, metal, and ceramic componentsfor various applicationsVolker PiotterKIT – die Kooperation vonForschungszentrum Karlsruhe GmbHund Universität Karlsruhe (TH)Content - Machinery and process- Submicron- and Nano Injection Moulding- Micro Powder Injection Moulding- 2-Component Micro Powder Injection Moulding (2C-MicroP IM)- Summary and OutlookV. Piotter      28.11.2013KIT – die Kooperation vonForschungszentrum Karlsruhe GmbHund Universität Karlsruhe (TH)MachineryDESMA FormicaPlast 2CWittmann Battenfeld MicroPowerArburgmicro moduleV. Piotter      28.11.2013KIT – die Kooperation vonForschungszentrum Karlsruhe GmbHund Universität Karlsruhe (TH)Closing + Heating of mold corePlastification of feedstock Evacuation of moulding toolInjection of feedstock Dwell pressure phaseCooling of moulding toolPrecise tool movementsEjection and handlingSpecialitiesHeating / Cooling = Variotherm-processnecessary for replication of high aspect ratiosInjection Moulding of Micro ComponentsV. Piotter      28.11.2013KIT – die Kooperation vonForschungszentrum Karlsruhe GmbHund Universität Karlsruhe (TH)Rheology InvestigationsStandard capillary rheometry tests are used to characterise shear flow of materials toaround 100 000s-1.Bradford University converted an injection moulding machine into a rheometer which iscapable of withstanding very high pressures (2800bar) and provides high injectionvelocities.This allows testing of materials to wall shear rates in excess of 10 000 000s-1.V. Piotter      28.11.2013KIT – die Kooperation vonForschungszentrum Karlsruhe GmbHund Universität Karlsruhe (TH)Rheology InvestigationsCourtesy of Ben WhitesideBradford University, UKShear thinning behaviour occurs until a critical limit above which the viscosity will risesignificantly.If a process is operating beyond this point, reducing the injection speed will actuallyhelp to fill the cavity.V. Piotter      28.11.2013KIT – die Kooperation vonForschungszentrum Karlsruhe GmbHund Universität Karlsruhe (TH)Multi-scale micro/nano manufactureLeap to mass fabrication => injection mouldingV. Piotter      28.11.2013Al 99.999% SubstrateMicromachiningAnodizationNi ElectroplatingSelective etching(Al dissolution)KIT – die Kooperation vonForschungszentrum Karlsruhe GmbHund Universität Karlsruhe (TH)Multi-scale micro/nano manufactureCourtesy of Guido Tosello,Technical University of DenmarkInjection MouldingMicro-NanoStructuredPolymer PartV. Piotter      28.11.2013KIT – die Kooperation vonForschungszentrum Karlsruhe GmbHund Universität Karlsruhe (TH)Nano Injection MouldingSEM figure of mold insertmade by e-beam writingand electroplating (KIT-IMT)Generation of nano-sized photonic crystalstructures for surface contrast microscopyKiel UniversityY. NazirizadehV. Piotter      28.11.2013replication in the nm-rangeminimum width ca. 80nm, PMMAKIT – die Kooperation vonForschungszentrum Karlsruhe GmbHund Universität Karlsruhe (TH)Micro System TechnologySource: Yole Development, March 2013V. Piotter      28.11.2013KIT – die Kooperation vonForschungszentrum Karlsruhe GmbHund Universität Karlsruhe (TH)Micro Powder Injection Moulding© www.pulverspritzgiessen.de„green“bodyV. Piotter      28.11.2013KIT – die Kooperation vonForschungszentrum Karlsruhe GmbHund Universität Karlsruhe (TH)PIM-Materials (selection)Metaltempering steel 42 CrMo 4, 40 NiCrMo 6 case-hardened steel 21 NiCr Mo 2, 16 MnCr 5tool steel 100 6W 5Mo 4 Cr 2Vstainless steel X20 Cr 13, X6 Cr 17austenitic stainless steel X2 CrNiMo 17 13 2 (316L, 1.4404)precipitation hardening steel X5 CrNiCuNb 17 4 (17-4PH, 1.4542)low-alloyed iron Fe2Ni, FeNi7softmagnetic materials carbonyl-Fe, Fe50Ni, FeSi3covar Fe 29Ni 17Cocopper Cu, CuNi50, CuFetitanium Ti6Al4V, TiAl7Nbnickel-base alloys NiCr 22 Fe 18 Mo, NiCr 20 Co 18 Tirefractory metals W, W-La2O3, WNiFe, WCu10, MoNb13, Mo20CuHard metals,Cermetscarbides, nitrides WCxCo, TiNcermets Mo-Al2O3, Fe-TiCCeramicoxide-ceramics Al2O3, ZrO2, ZTA, ATZnonoxide-ceramics Si3N4, SiC, AlNfunctional ceramics PZT, TiNV. Piotter      28.11.2013Components for spectacle frame locks316L, 0.028gOBE GmbH & Co. KG, GermanyKIT – die Kooperation vonForschungszentrum Karlsruhe GmbHund Universität Karlsruhe (TH)MicroPIMCapillary for fine pitch bondingtip-Ø=45µm, hole-Ø=19µmSPT Roth Ltd., CHV. Piotter      28.11.2013Scientific application: liquid jet nozzles for CFEL collaborative project between DESY and KITKIT – die Kooperation vonForschungszentrum Karlsruhe GmbHund Universität Karlsruhe (TH)Materialsmin. lat. Dimension[µm]min.Detail[µm]Aspect Ratio[isolated walls]Tolerance[± %]Roughness ** Rmax /  Ra[µm] Materials testedPlastics 10 <0.1 >20 (200*) 0.05 0.05  / <0.05 Thermoplastics, TPEMetals 50 10 >10 < 0.5 7  /  0.8 17-4PH, 316L, Cu, W, W-alloysCeramics <10 <3 <15 (0.1***) / 0.3 <3  /  <0.3 ZrO2, Al 203, ZTA, Al 2O3/TiN, Si 3N4* flow length to wall thickness ratio ** depending on mould insert*** after thorough process optimizationMicro Injection Moulding – General DataV. Piotter      28.11.2013KIT – die Kooperation vonForschungszentrum Karlsruhe GmbHund Universität Karlsruhe (TH)Multi-Component Parts Produced by MicroPIMFunctions integration by combining different materialsRealization of (im-)mobile connectionsReduction of handling and assembly expenditureMulti-Component Micro Powder Injection Mouldingsingle-piece fabrication+ assembly2C-MicroPIM– assemblyV. Piotter      28.11.2013KIT – die Kooperation vonForschungszentrum Karlsruhe GmbHund Universität Karlsruhe (TH)Multifunctional- / Multimaterial Productswith complimentary or  contradictionary properties, e.g.     conductive ↔ insulatinghard ↔ toughmagnetic ↔ non-magnetichydrophilic ↔ hydrophobictight ↔ porous→  2-Component MicroPIM (2C-MicroPIM)V. Piotter      28.11.2013KIT – die Kooperation vonForschungszentrum Karlsruhe GmbHund Universität Karlsruhe (TH)2-Component PIMHard metal WCxCo with differentCo-contents (16% and 6%)ARBURGFraunhofer Institute, IFAMCombination of a magnetic steel (17-4PH)with a non-magnetic steel (316L)2-Component MIM, steelAMT, SingaporeV. Piotter      28.11.2013KIT – die Kooperation vonForschungszentrum Karlsruhe GmbHund Universität Karlsruhe (TH)2-Component PIMconnection fixed movablebinders compatible not relevantpowder loading nearly equal φoutside > φinsidesintering-T nearly equal Toutside > TinsideCTE nearly equal nearly equalV. Piotter      28.11.2013KIT – die Kooperation vonForschungszentrum Karlsruhe GmbHund Universität Karlsruhe (TH)2C-MicroPIMFixed connections of different ceramicsZrO2Al 2O3Al 2O3ZrO2Realisation ofmovable connectionsV. Piotter      28.11.2013KIT – die Kooperation vonForschungszentrum Karlsruhe GmbHund Universität Karlsruhe (TH)- Enhancing technical performancelarger variety of materials, e.g. nanopowdersimprove simulation/predictabilitySummary and Outlook- Improving economic efficiencyflexible machinerysaving of material and energyV. Piotter      28.11.2013resistance to heat flow across the melt/mould interfacethermal contact resistance=> talk of Mr. MarhoeferKIT – die Kooperation vonForschungszentrum Karlsruhe GmbHund Universität Karlsruhe (TH)- Enhanced multi-component process variantstwo-component micro injection mouldingsinter-joining of PIM green bodies=> talk of Mrs. KlimschaLightweight applications:material compounds of C-fibresand metal insert parts by PIMinsert powder injection mouldingV. Piotter      28.11.2013Summary and OutlookKIT – die Kooperation vonForschungszentrum Karlsruhe GmbHund Universität Karlsruhe (TH)- Hybridization of micro processing technologies3D-MID and variants=> talk of Prof. HansenPIM + Additive ManufacturingV. Piotter      28.11.2013Summary and OutlookKIT – die Kooperation vonForschungszentrum Karlsruhe GmbHund Universität Karlsruhe (TH)- Bradford University- Technical University of Denmark- BMBF and State of Baden-Wuerttemberg- DESY- Deutsche Forschungsgemeinschaft DFG - Companies Arburg, Wittmann Battenfeld, DESMARKT, SPT Roth, OBE, Parmaco etc.- All colleagues at KIT  S. Antusch, N. Denker, T. Hanemann, J. Heneka,P. Holzer, E. Honza, A. Klein, T. Müller, K. Plewa, H. WalterThank you !AcknowledgmentV. Piotter      28.11.2013

Nano- and micro injection moulding of polymer, metal, and ceramic components for various applications

https://publikationen.bibliothek.kit.edu/230094056/3816439

Nano- and micro injection moulding of polymer, metal, and ceramic components for various applications

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