A review of micro-powder injection moulding as a microfabrication technique

Abstract

Micro-powder injection moulding (μPIM) is a fast-developing micro-manufacturing technique for the production of metal and ceramic components. Shape complexity, dimensional accuracy, replication fidelity, material variety combined with high-volume capabilities are some of the key advantages of the technology. This paper assesses the capabilities and limitations of μPIM as a micromanufacturing technique by reviewing the latest developments in the area and by considering potential improvements. The basic elements of the process chain, variant processes and simulation attempts are discussed and evaluated. Challenges and research gaps are highlighted, and potential areas for improvement are presented.

Micro and Nano Fabrication by Powder Metallurgy

“…Among the micro-manufacturing technologies, Micro Powder Injection Moulding (μPIM) [3] is capable of manufacturing metallic and ceramic micro-components and systems of complex shapes with very good dimensional accuracy combined with high volume capability. μPIM is an extension and miniaturized version of PIM…”

“…It has been shown that metallic powders in the semisolid state can be successfully used to fabricate a two layer functionally graded structure with one layer of aluminium-siliconcopper alloy and the other layer being SiC particles reinforced alloy. Figure 6 shows a schematic of semisolid powder processing set up [3]. …”

“…P/M process is well suited for manufacturing small and tiny components in large numbers especially by Powder Injection Moulding [2], an off-shoot of plastic injection moulding. In addition, other fabrication techniques such as Micro powder injection moulding (µ PIM) [3], Semisolid Powder Processing [4], Low pressure injection moulding (LPIM) [5], Nano powder injection moulding (NPIM) [6], Rapid Proto Typing (RPT) [7], Micro sacrificial plastic mould insert PIM (µ-SPiPIM) [8], Co-powder injection moulding (2C-PIM) [9], Selective Laser Sintering (SLS) [10], Selective Laser Melting (SLM) [11], Laser Micro Sintering (LMS) [12], Electron Beam Melting (EBM) [13] and Nano Forging by FIB/SEM [14] have been adopted to fabricate micro and nano sized components. This paper will discuss the above processes explaining the principle, the equipment used along with specific examples.…”

Validation of precision powder injection molding process simulations using a spiral test geometry

“…Together with the number of applications and the interest in the technology, the demand for reliable simulation tools increases [1,2]. In (powder) injection molding, simulations are a very useful tool to accompany and support the design process of the actual part as well as of the mold and the process.…”

Water soluble Invar 36 feedstock development for μPIM

“…As remarked by Heaney (2012) and many other authors, this promising technology has experienced rapid growth due to the rising demand for the application of micro components. Attia and Alcock (2011) compiled a thorough revision of PIM. Micro components are classified into the three categories, namely: micro parts, microstructured components and micro-precision parts.…”