Abstract
A novel process, powder co-injection moulding (PCM), a development of powder injection moulding is described. A twin-barrel injection moulding machine has been used to inject two different powder/binder mixtures sequentially into a mould. The new process allows surface engineering during powder injection moulding rather than as a post-production stage in the manufacturing cycle. Two examples of co-injection moulding are described. The first considers a polymer component having a particulate or fibre-reinforced skin layer. The second discusses the production of dense, layered ceramic or metal components having a corrosion- or wear-resistant surface layer. Modelling of the PCM process is being undertaken using a commercial finite-element modelling program, C-Mold and an example of how this may be used to predict coating thickness is presented.
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