Development of Two-Component Micropowder Injection Molding (2C MicroPIM): Characteristics of Applicable Materials

Abstract

The progress in microinjection molding has paved the way for the fabrication of complex components. Particularly, the integration of different functionalities made possible by two-component injection molding is a challenging facet of this technology. For the production of robust microdevices consisting of two different metals or ceramics a special variant of this technology has to be implemented: two-component micropowder injection molding (2C MicroPIM). The study presents the materials and powder combinations suitable for 2C MicroPIM. The investigations included considerations on materials behavior during feedstock compounding, injection molding, debinding, and sintering of the assemblies. As a result of dilatometric measurements and on the basis of theoretical considerations and characterization of a 2C MicroPIM part at the phase boundary the requirements beneficial for either a fixed or a movable junction were defined. A shaft-to-collar connection was used to demonstrate the applicability of the selected materials. The investigated ceramic powders and the organic components for the feedstock development for the realization of a shaft-to-collar connection with 2C MicroPIM are clearly applicable when a dispersant like stearic acid is added.