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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Introduction

Our company

~ 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 CIM
Metal Injection Ceramic Injection
Moulding Moulding

Iron and Steel,

Oxides, Nitrides,
Non Ferrous Alloys,
Carbides, Ferrites
Heavy Metals

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At a glance

Exploiting injection moulding potential

In focus: complex components with high unit volumes
Production (thousand units)
1000

Ceramic injection
moulding
100 Axial / Isostatic (CIM)
pressing

10
Low-pressure
injection moulding,
Slip casting
1
Low Medium High
Part complexity

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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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Multi-stage: the manufacturing
process

Process sequence overview

Feedstock Injection Debinding Sintering
preparation moulding

Secondary
Regrind
operation

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At a glance

Reliance on comprehensive support

Process
Expert consulting
sequencethroughout
possible
from production
component
the
secondary
process
process
point-of-view
processes
chain
point-of-view
Powder Green Brown
Feedstock Finished part
Binder compact compact

Feedstock Injection Debinding Sintering

preparation moulding
Injection moulding
Pre-mixer Debinding unit Sintering furnace
Breaking machine Secondary
Mixing unit
sprues Robotic system
operation
Wide range of injectable
Granulating unit feedstocks
Grinder Mouldavailable
/ jaw crusher Grinding machine
Unique ARBURG service range
Temperature control
Paint shop ...
unit

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Multi-stage: the manufacturing
process

Typical values for powder injection moulding

Dimensions Length [mm] < 100
Diameter < 50 .
Wall 0.5 12
thickness
Bores > 0.1
Edge radius > 0.1
Tolerances Normal [%] +/- 0.3
Best +/- 0.1

Volumes [cm] 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

MKS GmbH
SPT Roth
Maxon Ceramics Maxon Motor RSG Solingen

Hardness Complexity Miniaturisation Flexibility

More than 40 companies in Europe are making

ceramic products using injection moulding
technique
Sources: Internet, Ceramtec

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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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Breakthrough CIM applications

Grinding disk for industrial coffee machines

Solution: metal replacement by CIM part
Higher lifecycle because of hardness
Nickel free
Better grinding properties
Chemical resistant

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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

Tweezers ZrO2 elastic

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Breakthrough CIM applications

Punch rivet Al2O3 Dimension / weight

height 4 mm / app. 0,2 g

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Breakthrough CIM applications

Cell Phone Housing

ZrO2, coloured, polished

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Breakthrough CIM applications

CeramCool Heat sinks

(alumina / aluminum nitride)
for high power LED-systems

Source: Ceramtec
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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 condition control panel

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
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Breakthrough CIM applications

Central control unit

Central control unit
Matching surface feel / turning
moment to higher mass Rotation
Roundness at complex inner swivel
contour (rotation swivel)
Different surfaces (polished /
matte) within one part
Meeting EMV-protection
standards (circle cover) Circle cover
Cover
Polishing extreme concave
surfaces

Source: Oechsler
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Breakthrough CIM applications

Gear selection lever

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

Source: Oechsler
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Breakthrough CIM applications

Probe head Si3N4

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Breakthrough CIM applications

Probe head Si3N4

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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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Breakthrough CIM applications

Implant ZrO2

Quelle: ZDA Quelle: ZDA

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Breakthrough CIM applications

Abutment ZrO2

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

1. Mould lost core (POM)

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Future Applications

Lost Core Process

2. Overmould lost core with Feedstock

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Future Applications

Movable Link, assembly moulded

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Future Applications

Two Component Cup, Porcelain

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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/pul
ver-spritzgiessen-pim/pim-
newsletter-subscribe

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Breakthrough CIM applications

ARBURG GmbH + Co KG Tel.: +49 (0) 7446 33-0

Arthur-Hehl-Strasse Fax: +49 (0) 7446 33-3365
D-72290 Lossburg E-mail: contact@arburg.com
www.arburg.com