Micro CIM for Precision Instruments and Medical Applications. SmartManufacturingSeries.com

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1 Micro CIM for Precision Instruments and Medical Applications SmartManufacturingSeries.com

2 Outline Discussion of micro-scale ceramic injection molding experience Introduction to CIM Case Studies Conclusions Future Work

3 History of CIM Technology Ceramic Injection Molding Founded in the 1940 s for spark plug manufacturing and improved versions came from advancement in plastic injection molding. Is a version of Powder Injection Molding (PIM) such as Metal Injection Molding (MIM) 1. Ceramic powders are mixed in a carrier (binder) 2. Parts are injection molded into green shapes 3. Green parts are fired (sintered) depending on feedstock chemistry/composition

4 Why CIM? Strengths of this technology Parts made in ceramic materials are very expensive to machine when fully fired. The ability to near-net shape parts is very economical, particularly when shapes are too complex to press and/or machine Typical production volumes 300,000 pieces Use of virtually all ceramic powders Good precision/repeatability Manufacture complex geometries

5 Why CIM? Strengths of this technology Parts typically range in size from 0.3mm (.0118 ) up to larger shapes with tolerances less than 5-10μm (0.0002" ") and mass 0.5g minimum High hardness and mechanical strength Highly resistant to heat, pressure, corrosion and wear Physical and dimensional stability Chemically inert Biocompatability Low electrical loss & high dielectric strength Thermally insulative

6 Raw material CIM Feedstock

7 Why not CIM? Technology weaknesses Ceramics are traditionally made by pressing or extrusion processes, which are typically faster and lower cost, at least when making simpler geometries. High tooling cost Slower firing process Less economical in very low volume or very high volume

8 Micro-CIM Specialized equipment For precise control of shot size and to generate high pressures, a very small injection molding machine screw (8mm) is used. Precautions considered were: Compatibility of standard feedstocks Number of units in the field (i.e. reliability, support, operation knowledge, etc.) Usage specifically with CIM feedstocks Advantage over conventional methods (machines with normal screws)

9 Micro-CIM Precision and control of shot size Scale 0.5mm

10 Case Study #1 Ceramic Sample Pan for TGA Machine TGA (Thermogravimetric Analysis) machines burn a sample and measure the weight loss during combustion to analyze the decomposition, etc. Ceramic pans (aka crucibles, liners, cups) are commonly used for many applications since they are, Chemically inert High temperature stability Non-outgassing Low cost and re-usable But not all ceramic pans are created equal!

11 Case Study #1 Ceramic Sample Pan for TGA Machine

12 Case Study #1 Ceramic Sample Pan for TGA Machine Manufacturing thin wall parts magnifies the challenges inherent with CIM technology! Certain considerations in this case include: Gate size and location only medium pressures can be used before you start pushing the ceramic out of the binder Part handling (removal from mold, firing, etc.) Mold cavity wear and tooling precision for a uniform wall, and concentric, round part High purity 99.8% Al 2 O 3 fired to full density specialized feedstock for 1-step firing Order volume = 10,000 to 20,000 pcs/yr so a 4- cavity mold insert in carbide steel required

13 Case Study #1 Ceramic Sample Pan for TGA Machine Manufacturing these led to tooling format discoveries and investment in technology for higher consistency in quality 1:1 gate size to wall thickness ratio Granulator with fine screen (Ø1mm) De-dusting unit

14 Case Study #2 Ceramic Insulators for Medical Application Project Scope: Manufacture micro insulators with two different thru-hole lead-in formats (tapered and counterbore) in alumina for customer evaluation.

15 Case Study #2 Ceramic Insulators for Medical Application Project Scope: Manufacture micro insulators with two different thru-hole lead-in formats (tapered and counterbore) in alumina for customer evaluation. Constrained in tooling budget, a hybrid mold was made to save cost Competing technology = micropressing Glass sealing application, very low tolerance for defects Lot quantity 1,000 pcs of each insulator

16 Case Study #2 Ceramic Insulators for Medical Application Co-pack (micromolder) with unit cavity mold Parts weigh 0.1g Injection pressure 1400 Bar (20,000 psi) Injection time 0.8s

17

18 Case Study #2 Ceramic Insulators for Medical Application Approach: Use of stack mold with interchangeable core pins for formation of the two different ID formats, unit-cavity, manually operated. Gate size and type different than case study #1 which used a 1:1 part thickness to gate diameter ratio. Edge of parts would break at gate location Feedstock different from case study #1 although still 99.8% alumina, binder system and base powder higher quality, more appropriate for potential high volume manufacturing in future Tolerances on dimensions tight but achievable in as-fired condition (no post-fire grinding required)

19 Case Study #2 Ceramic Insulators for Medical Application Tape gate (example)

20 Case Study #2 Ceramic Insulators Flash around pin Edge defects

21 Conclusions Critical process control balance between short shot and flash Feedstock management, molding cadence impossible with manual mold Micro parts micro defects! Micro drilling holes instead (similar to ceramic fiberoptic ferrules) Unit: in.

22 Future Work Nano powders for feedstocks Advanced tooling/design Real time inspections/quality Robotics implementation Micro-drilling green parts

23 Thank you! Thomas Henriksen

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