Breakthrough applications created by ceramic injection moulding technology (CIM)€¦ · ·...
Transcript of 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
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Our company
Introduction
~ 2,400 employees worldwide Consolidated turnover 2013: 480 million euros 2014: 548 million euros Export share ~60%
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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
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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
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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
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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
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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)
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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
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Process sequence overview
Multi-stage: the manufacturing process
Feedstock preparation
Injection moulding
Debinding Sintering
Secondary operation Regrind
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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
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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
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Breakthrough CIM applications
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
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Breakthrough CIM applications
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
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Breakthrough CIM applications
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
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Grinding disk for industrial coffee machines Solution: metal replacement by CIM part • Higher lifecycle because of hardness
• Nickel free
• Better grinding properties
• Chemical resistant
Breakthrough CIM applications
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Breakthrough CIM applications
Puncture Plate for Coffee Capsules • ATZ
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Breakthrough CIM applications
Scalpel ZrO2 „X-Ray invisible“, Sharp
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Breakthrough CIM applications
Punch rivet Al2O3 Dimension / weight height 4 mm / app. 0,2 g
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Cell Phone Housing ZrO2, coloured, polished
Breakthrough CIM applications
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CeramCool® Heat sinks (alumina / aluminum nitride) for high power LED-systems
Source: Ceramtec
Breakthrough CIM applications
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Breakthrough CIM applications
Watches ZrO2
• Parts: Watch housing, Bezel or Wristband
• Coloured or natural Zirconia
Source: Internet
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Breakthrough CIM applications
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
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Breakthrough CIM applications
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
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Breakthrough CIM applications
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
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Breakthrough CIM applications
Probe head ZTA 20 Dimension / weight D 1,0 – 7,4 mm / ~ 0,04 g
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Breakthrough CIM applications
Implant ZrO2 • Good attachment of cells
• Biocompatible
Source: TAV medical
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Abutment ZrO2
Breakthrough CIM applications
Quelle: TAV medical Quelle: TAV medical
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Future Applications
Gas Internal Pressure Moulding at MIM and CIM • Weight reduction and reduced process times
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Future Applications
Lost Core Process • 2. Overmould lost core with Feedstock
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Infomaterial
ARBURG PIM-Website (german / english)
PIM-Newsletter Subscription
Download Section
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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
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Breakthrough CIM applications
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