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. Development of a feedstock formulation based on polypropylene for micro-powder soft embossing process of 316L stainless steel micro-channel part.

International audienceThis study presents the results of micro-replication of different powder feedstocks samples. The feedstocks of metal powder and plastic binder with various solid loading in the range from 40% to 75% were prepared. The different feedstock comprises 316 L stainless steel, Fe\Ni 8%, orWC-Co and amulti-component binder system. Suitable polymers/powder formulations for the hot embossing were chosen and characterised by thermogravimetric analyses (TGA), mixer measurements and capillary rheology testing in order to check and quantify the viscosity and homogeneity of all the developed feedstocks. The photoresist (SU-8) was used as a structural material that was deposited onto the Si wafer to obtain the micro-fluidic systems with low roughness. Then the elastomeric mouldwas obtained using casting with one face that contains all the details of the originalmaster, very well defined and smooth sidewalls. The objective of the paper is to develop metallic micro-structured die mould cavities with higher quality using hot embossing process with various different powder loaded polymers. However, a rapid prototyping process was adapted for fast and cost-efficient manufacturing. This study compares the capacities of three different metallic powders to emboss of the metallic replications by hot embossing, the dimensional stability, the mechanical strength and particularly hardness of sintered components. The results show that the feedstock can be used for the manufacturing of the micro-fluidic die mould cavities with a low roughness, proper dimensions and good shape retention

Micro-metal injection moulding process technology is one of the key technologies to satisfy the increasing demands for smaller parts associated to miniaturisation and fictionalisation in different application fields. The process combines the shape-making capability of polymer by hot embossing with sintering technology to produce complex, high density metal parts with outstanding properties. The present work focussed on elaboration and characterisation of feedstock based on 316L stainless steel powders for micropowder embossing process. In this paper, the rheological specifications of the binder and the feedstock were observed by means of capillary rheometry. Thermogravimetric analysis was carried out on feedstock in order to understand decomposition behaviour of the binder components. The effects of sintering temperature on the dimensional stability, and particularly hardness of sintered components, were investigated. The results show that the feedstock can be used for the manufacturing of the micro-fluidic die mould cavities with a low roughness, proper dimensions and good shape retention.

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