After forming, the part goes through a two-stage process. First it’s debinding to remove the binder, followed by sintering in a high temperature furnace to form a fully dense ceramic component. Sintering is the process of heating the material to a temperature below the melting point but high enough to allow fusion of individual particles and densification of the material.
During sintering, the component shrinks by as much as 20% while retaining the original geometric shape. With good process control, it is possible to achieve a uniform and repeatable shrinkage leading to tight tolerances, obviating any need for machining of the part afterwards.
Advantages of CIM First, during the design phases, Indo-MIM conducts mould flow simulation and analysis in order to optimise the part and mould design. By performing this analysis early in the design process, prior to commissioning the injection mould, many problems can be addressed and improvements can be implemented quickly at low cost and without causing expensive delays in the production schedule.
A second key factor in achieving tight tolerances and high repeatability is quality control during the mixing process to create a homogeneous pelletised feedstock. The ceramic particles must have a consistent size and they must be distributed evenly in the polymer binder. The use of sub-micron powders allows for smaller features that would otherwise not be possible with larger
granulate-based forming methods such as dry pressing and such precautions are well taken care of in advance to avoid any mishap. And the third critical refinement implemented is cavity pressure containment and control. Cavity pressure is the process variable that correlates most directly with part quality.
Ceramic materials are tough enough to withstand acid corrosion, extreme heat, heavy friction, high pressure, ongoing abrasion and exposure.
CIM — a trend change Anything that makes things simpler and more convenient has a stronger hold than competing methods, and the same goes for ceramic injection moulding, too. This new process is attractive because it is repeatable and customers receive highly consistent quality with little part-to-part variation and with fewer rejects and proven statistical process control, incoming regular checks by the customer is no longer required.
The advanced CIM process gives engineers more versatility in the use of ceramics when designing new products and replacing plastic and metal components that fail to perform adequately and this changing trend, in turn, has allowed production engineers and product designers to improve productivity, lower manufacturing costs and improve product performance.
INDO-US MIM Tec. Pvt. Ltd.
www.indo-mim.com
Sonor
Sonorus 1G
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energy savings
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ark Autònoma, 23 5 Call us now for a free test at: +34 935 944 725
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EX CEEDING THE LIMITS OF MICRO-MOLDING 33 | commercial micro manufacturing international Vol 6 No.6
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