brochure: powder injection moulding - arburg

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Cost-effective solutions for metal or ceramic parts

Powder injection moulding

Focus

www.arburg.com · 0920162

The need for highly resilient and precise components is growing in virtually all industrial sectors. With the injection moulding of powdered materials (PIM) you have access to a technology that offers new design options for highly complex components made from metal (MIM) or ceramics (CIM). Consistently high-quality parts with details down to the micrometer range can be produced in high volumes.The great advantage: freedom of shape. Like no other process, powder injection moulding enables near-final-contour part production, including internal threads, difficult undercuts, gearings and free-form surfaces. PIM parts dis-play mechanical and material properties which are comparable to those of con-ventional metal and ceramic parts. Tech-nology of the future with high added value – so why not benefit?

Green compact

Brown compact

Expert consulting throughout the entire process chain

Feedstock

DebindingFeedstock preparation

Injection moulding Sintering

Finished part

ReworkingBreaking sprues

Unique ARBURG service range

Binder

Powder

Example: burner for HID bulbs. Ceramic injection moulding enables the efficient production of smaller parts with equal performance.

At a glance

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Exploiting injection moulding potentialPIM technology enables the production of complex parts in high unit volumes. The production process can be highly auto-mated, production can be quickly converted to other products. ARBURG injection moulding technology is equally flexible:• with the modular range of hydraulic and

electric ALLROUNDERs• with application-specific equipment

versions, e.g. for multi-component technology

• with the appropriate PIM-specific adapta-tion of the injection units in terms of geo-metry and wear resistance

As a result and through close co-operation with the leading material, mould and fur-nace technology manufacturers, ARBURG develops optimum, customised, user-spe-cific solutions.

Reliably achieving qualityWith the freely-programmable SELOGICA control system on each ALLOUNDER, PIM processing can be implemented for maxi-mum quality long-term. This is ensured, not only thanks to the position-regulated screw, but also to the fully integrated robotic tech-nology for gentle handling of the fragile moulded parts, the so-called “green com-pacts”. Functions such as compression in-jection moulding and evacuation also en-sure a high level of process stability and re-peat accuracy. The graphic symbols as well as the direct plausibility checking during sequence pro-gramming permit a good overview, and en-sure simple setup of even complex produc-tion processes. Moreover, numerous options are available for optimising, monitoring and documenting production processes.

Reliance on comprehensive supportARBURG is also a pioneer on the market for powder processing. Customers can rely on the corresponding comprehensive consult-ing, technology and service offerings throughout the process chain This is en-sured by a cross-departmental team of PIM specialists who have already set up several hundred systems world-wide.The support offerings range from material selection and preparation, moulded part-compatible design, individual machine and mould configuration, through to the debinding and sintering process. Whether for process optimisation, material or mould testing: At ARBURG’s in-house powder lab-oratory, customer-specific tests can be per-formed and sample parts produced. In-depth training courses complete the unique range of services.

Example: laptop catches. Through the use of metal injection moulding, highly resilient components can be produced in any shape

for high-volume production.


Machining technology? Stamping technology? Your product ideas can no longer be implemented cost-effectively in high unit volumes using conventional production methods. It therefore makes sense to take a closer look at powder injection moulding. With this alterna-tive method, you have almost unlimited design freedom with regard to your components, generate virtually no waste and achieve a high degree of sur-face quality as well as dimensional sta-bility. Time and cost-intensive rework-ing of parts is dispensed with. Your production becomes highly economical and efficient through the comprehen-sive linkage of all process steps. You thus produce your PIM parts just as you always expect to: reliably, flawlessly and smoothly.

Feedstock preparation: mixing powder with binderIn principle, all fine-grained, sinterable pow-ders can be mixed with a suitable polymer-based binder and then processed on injec-tion moulding machines. During mixing, the binder and powder are mixed to a homoge-neous compound, the feedstock. The selec-tion of powder materials is extensive: In ad-dition to the oxide ceramics and steels, hard and precious metals as well as cermets can also be used. Material manufacturers supply a steadily growing selection of injectable feedstocks for metals and ceramics, includ-ing magnetic versions, for example. Further-more, customer-specific feedstocks can also be developed and produced.

Injection moulding: moulded part manufactureFor the injection moulding of powder mate-rials, similar mould and process technology is used as that for plastics processing. The binder content of the feedstock is melted in the plasticising unit through heat before be-ing injected into the mould at high pres-sure. Robotic systems are generally used to remove the hardened moulded part, the so-called “green compact”, from the mould without damage.Material and mould changes can be per-formed in a short time. “Just in time” pro-duction can be easily implemented, as can unmanned volume production using the ap-propriate automation solutions.

Multi-stage: the manufacturing process

Perfect preparation: powder properties decisive

for process and component.

Precise contours: injection moulding key to subse-

quent part quality.

Extremely precise: meeting the strictest tolerances

with powder injection moulding.

0.05

0.06

0.075

0.15

0.25

0.5%

Nominal dim. mm Tolerance +/- mm+/-

<3

3-6

6-15

15-30

30-60

>60

of nominal dimension


In order to demonstrate the complete powder processing procedure to inter-ested parties in practice, ARBURG has a unique PIM laboratory.

Here, all the steps from feedstock mixture, preparation and injection moulding through to debinding and sintering of the moulded parts can be carried out under laboratory conditions. In-depth consulting by experi-enced specialists is also available – on suita-ble powder/binder mixtures, for example, on green compact production, on downstream processes, as well as on machine and mould design. A variety of test parts can be injec-tion moulded on in-house moulds.

ARBURG also develops and tests feedstock mixtures for customers. In order to optimise the feed characteristics, the feedstock can be processed into a homogeneous granulate.Finally, the PIM laboratory is equipped with the necessary facilities in order to perform all the debinding processes currently availa-ble on the market.

PIM laboratory

Debinding: removing polymerDuring debinding, the polymer component is removed from the green compact using either a catalytic process, dissolving (e.g. with water or acetone), or thermal decomposition. This process can be effec-tively supported by suitable process control measures. When the binder is removed, the moulded part becomes what is known as a “brown compact”. In this condition, the parts are po-rous, fragile and relatively unstable. The debinding system must be adapted to the specific binder system employed.

Sintering: mechanically stable bondingIn order to securely bond the particles of the brown compact, the part is sintered by further heating. For this purpose, a certain

furnace atmosphere and tem-perature-time profile must be maintained. The final moulded part, which

becomes denser by 15 to 25 %, is produced by diffusion

and/or the formation of liquid phases and grain growth. Injection moulded,

sintered parts are characterised by great homogeneity and high material density. Fine powders and suitable mould technol-ogy ensure outstanding surface qualities and minimal tolerances.

High-quality sintering: moulded parts shrink iso-

tropically, i.e. equally in all directions.

Individually debinded: in suitable atmosphere,

dependent on binder and moulded part.


The injection moulding of ceramic or metal powders does not differ sig-nificantly from the processing of filled plastics. This especially applies to con-sistently high quality during volume production. Faults in the moulded part such as cracks, for example, can no longer be remedied during subsequent debinding and sintering. We consequently place great value on reproducible, flawless injection mould-ing production. Only then can you as a PIM producer be on the safe side and smooth-running production be ensured.

Basis: repeat accuracyThanks to three-platen technology, clamping units with four tie-bar guidance and central force application, as well as servo-regulated mould movements, the clamping units en-sure precise moulding, protection of the mould and precise positioning. The high-pre-cision technology effectively counteracts burring. Depending on the requirements, hy-draulic or electric machine options can be used. Reproducible mould filling and particu-larly high moulded part quality are achieved by means of the unique position regulation of the screws. This minimises rejects.

Important: adapted plastificationWith ARBURG, the non-return valve can be configured according to the relevant particle size of the powder, ensuring a high degree of process stability, even in the case of coarse powders. The geometry of the

PIM screws is always designed for the nec-essary low compression. Overheating and decomposition of the feedstock is thus reli-ably prevented.

Effective powder processingSprues are kept short through extension of the PIM nozzle length. The expensive feed-stock is optimally utilized and the moulded parts are always perfectly compressed. Ow-ing to the abrasive properties of the pow-der/binder melt, the injection unit is de-signed to be extremely wear resistant.Cost-effective operation with short setup times is also important in the case of com-plex production processes. On the ALL-ROUNDERs, this is achieved through the simple replacement of the cylinder module and screw via the swivelling injection unit and the central coupling of all the supply connections for the cylinder module.

Highly wear-resistant: powder-compatible non-

return valves.

Effective savings: short sprues thanks to extended nozzle length.

Further information: Hydraulic ALLROUNDERs brochure

Electric ALLROUNDERs brochure

Unlimited: the possibilities of modular machine technology


ARBURG has combined the necessary basic equipment for optimum processing of powder materials into one package. As standard this includes:

• MIM or CIM cylinder module with specific configuration of the non-return valve

• Extended PIM nozzle length• Position-regulated screw• Additional nozzle heater circuit• Interfaces for vacuum devices• SELOGICA functional expansions

There are also additional expansion options. These include:• Vacuum devices• Robotic systems with various kinematics• Universal compression injection moulding

via ejector or core pull

Wide variety of optionsIn principle, all ALLROUNDERs are suitable for powder processing. The machines can be individually adapted with a • variety of hydraulic expansion stages• flexible combination of injection and

clamping units• various injection unit arrangement

options – e.g. for multi-component injection moulding

• task-specific equipment packages – e.g. for gas injection moulding technology or in-mould lamination of green sheets.

Complete solutions precisely adapted to the applications are created by means of integra-ted peripherals and automation solutions, for part removal and set-down, for example.

Custom adapted: mould venting with modular

vacuum technology.

Careful handling: gentle part removal with

robotic system.

Unlimited: the possibilities of modular machine technology PIM package


1 Reliable evacuation

One important technique for powder pro-cessing is venting of the mould prior to in-jection. This prevents air inclusions, joint line problems and binder migration, as well as ensuring complete mould filling with uniform filling characteristics. Venting can be programmed with great flexibility via dedicated symbols, whereby integration of all common vacuum concepts is possible. Moreover, SELOGICA also utilises signals

from vacuum devices for process and qual-ity control. This ultimately results in the transparent control and documentation of the entire venting process directly on the control screen.

Maintaining control over sophisticated machine, mould and robotic technology is the domain of SELOGICA. With this setting and monitoring system, you can quickly set up both simple and complex injection moulding processes, operate them intuitively and perform reliable optimisation. In other words: central management. All technical features of the SELOGICA control system, such as the graphical sequence editor, are also ideally suited for the processing of powder materials and aimed at making operation quicker, more reliable and more convenient. Here too, ARBURG provides you decisive application advantages: because we have already integrated all the necessary functions for high-quality and cost-effective part production in the SELOGICA system.

Further information: SELOGICA control system brochure

Suitable for all requirements: the SELOGICA control system

User-friendly: simultaneous monitoring of robot

and machine sequence.

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• Control centre for the entire injec-tion moulding technology

• Convenient sequence programming with graphic symbols

• Immediate plausibility checks• Freely programmable production

sequences • Common data record for the entire

production unit• Water-cooling for continuous

temperature control in the control cabinet

Universal compression injection moulding

Fully integrated peripherals

Reliable evacuation

HighlightsSuitable for all requirements: the SELOGICA control system

2 Universal compression

injection mouldingOne important function for directed mould filling without the formation of open jets is compression injection moulding. Here, the ejector or core pulls are actively moved dur-ing injection. The compression sequence is both controlled and freely-programmable via SELOGICA, for example through individual selection of the starting conditions.

3 Fully integrated peripherals

The SELOGICA central control system inte-grates all the necessary peripherals, for ex-ample robotic systems. To ensure particu-larly gentle part handling, all processes can be programmed as a function of and syn-

chronously with machine movements. As part of the overall sequence, they appear with dedicated symbols in the sequence editor and can be centrally monitored.

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Due to the high degree of design freedom with regard to the parts, the wide range and combination of differ-ent materials and, above all, the cost-effectiveness of the production process, powder injection moulding is an ideal process for reliably and effectively man-ufacturing complex components from metal (MIM) or ceramics (CIM). Fur-thermore, technologies such as multi-component injection moulding extend the range of possible applications. In addition to our innovative and sophis-ticated technology, from the standard solution to the system solution, you can also rely on our extensive expertise in applications technology. Whenever you need it. However you need it – for the best, most cost-effective solutions.

1 MIM for combustion engines

One example of the high performance now achieved in the injection moulding of metal-lic powder materials is demonstrated by the high-toughness, high-strength intermediate lever arm used for valve actuation (Valvetro-nic) in a six-cylinder BMW engine. This par-ticular production example very clearly illus-trates the benefits of the ALLROUNDER in-jection moulding technology. The produc-tion process runs extremely smoothly and very reliably, even during shift operation. This enables high-quality zero-faults produc-tion. The injection unit is adapted to the specific requirements of the MIM process. A highly competent Service department, which is available at short notice, completes ARBURG’s service offerings.

2 CIM with minimal tolerances

Ceramic ferrules are used for connecting optical fibre bundles for data transmission. The concentricity and the highly accurate drilling of the through-hole measuring just 0.125 mm is a decisive factor with respect to the quality of the components. In com-parison to other production processes, the ferrule can be manufactured with a higher degree of precision when powder injection moulding with a hydraulic ALLROUNDER is used. This application allows ARBURG’s po-sition-controlled screw to demonstrate its full potential. Tolerances of ±10 μm are pos-sible for concentricity, whereby the finishing work is reduced to a minimum. Part re-moval via the MULTILIFT H robotic system delivers additional process reliability.

Utmost precision: injection moulding of ceramic

ferrules to meet the sharpest of tolerances.

Dependability: stable and reliable volume production with PIM system solutions from ARBURG.

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Application examples


3 Articulated metal joint

Multi-component injection moulding also enables the combination of different pow-der materials in a single component. Here, the different shrinkage characteristics of the materials during sintering are exploited in order to produce permanent, moveable con-nections that could not be manufactured by conventional means. The ball joint is pro-duced on a three-component ALLROUNDER. Here, the third component only serves to support the green compact and is removed following sintering. The three injection units, as well as all mould and robotic se-quences can be fully integrated into the central SELOGICA control system.

4 Ceramic grinding disc

The efficient production of technical ce-ramic parts, grinding mechanisms for exam-ple, can be implemented using powder in-jection moulding. More stringent tolerances can be met with regard to the injection moulded parts, reducing the amount of cof-fee required for each cup. In order to pro-duce the ceramic grinding discs, the melted feedstock is injected into the mould using a staged injection profile. The parameters are specially adapted to the component being produced. A MULTILIFT robotic system re-moves the grinding discs and sets then down onto the debinder and sintering trays in a specified pattern. The total cycle time is between only 15 and 25 seconds.

5 Hard alloy radius milling cutter

Only with powder processing can hard alloy cutting tools be produced without restric-tions in terms of moulded part geometry. Injection moulding enables the trouble-free production of hard alloy cutters, including simultaneous demoulding of an internal thread for screwing the “disposable tips” onto a shaft. Fully automatic production is possible, saving time and expense. Owing to the very short sprues, considerable ma-terial savings are also achieved. A wide va-riety of cutting geometries can be pro-duced in the mould by simply changing re-placeable inserts. Thanks to the PIM pro-cess, only regrinding of the seats and cut-ting edges is necessary.

Red hot: the material properties are only achieved

during sintering.

Great freedom: feedstocks can be individually

developed and injection moulded.

Three-fold combination: several materials can also

be processed simultaneously.

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Distances between tie bars from 170 x 170 to 920 x 920 mm | Clamping forces from 125 to 5,000 kN | Injection units from size 30 to 4600 (according to EUROMAP)

© 2016 ARBURG GmbH + Co KGThe brochure is protected by copyright. Any utilisation, which is not expressly permitted under copyright legislation, requires the previous approval of ARBURG.

All data and technical information have been compiled with great care. However we accept no responsibility for correctness. Individual illustrations and information may deviate from the actual delivery condition of the machine. The relevant valid operating instructions are applicable for the installation and operation of the machine.

ARBURG GmbH + Co KG

Arthur-Hehl-Strasse · 72290 Lossburg · Tel.: +49 7446 33-0 · www.arburg.com · E-Mail: [email protected]

With locations in Europe: Germany, Belgium, Denmark, France, United Kingdom, Italy, Netherlands, Austria, Poland, Switzerland, Slovakia, Spain, Czech Republic,

Turkey, Hungary | Asia: People’s Republic of China, Indonesia, Malaysia, Singapore, Taiwan, Thailand, United Arab Emirates | America: Brazil, Mexico, USA

For more information, please go to www.arburg.com.

ARBURG GmbH + Co KG

DIN EN ISO 9001 + 14001 + 50001 certified 5227

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brochure: powder injection moulding - arburg

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