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POWDER INJECTIONMOULDING

InternationalSpecialised Skills Institute Inc

ISS Institute Inc.October 2007 ©

Arnold RowntreeISS Institute/Italy (Veneto) Fellowship

Fellowship funded by the International Division, Victorian Government

Published by International Specialised Skills Institute, Melbourne.

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October 2007

Also extract published on www.issinstitute.org.au

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Executive Summary

Powder Injection Moulding PIM is a growing technology widely practised around the world over the past three decades but in Australia only by only one company. Ceramet Technologies based in Ballarat (Victoria), is growing quickly by aggressively pursuing PIM technology and exporting the vast majority of its product.

The adoption of PIM technology has been slow in Australia with local design engineers being limited by only designing for traditional methods of manufacture and additionally, not perceiving themselves as potential players in global markets. This lack of knowledge and ‘know-how’ locks Australian firms out of competitive capabilities and commercial opportunities. Industry estimates of the annual growth of PIM internationally over the last decade are up to 30%, an indication of its significance for engineering and the economy. The growth is expected to continue in the 21st century.

The aim of this fellowship is to identify and acquire the skills and knowledge critical to enable the greater take up and employment of Powder Injection Moulding technology in Australia to satisfy existing global demand and potential local demand.

Specific areas of study and development for the current study:

• Material selection procedure for specific parts• Observation of the equipment used and the process for feedstock formulation• Acquire knowledge of injection moulding machine characteristics and configuration for

PIM applications• Investigate how the PIM process affects part design• Observe the differences between PIM and plastic mould design• Observe debinding equipment in operation and the processing steps• Understand sintering equipment and associated processing• Engage in discussion of toolmaking education and skill availability• Observe the layout and equipment involved in a research facility setup

The overseas program was designed to explore the identified skills and knowledge gaps and to obtain the information necessary to return to Australia equipped with the knowledge and ideas essential to ensuring enhanced teaching practices and content delivery. It was essential that the study tour provided a platform for Rowntree to develop effective experiences and opportunities for others to maximize their learning; experiences essential to promoting and improving the overall acceptance of Powder Injection Moulding in this country.

In order to meet the fellowship aims and objectives the following sites were visited:

Singapore: Singapore Institute of Manufacturing TechnologyItaly: Veneto Innovazione, Assindustria Rovigo, Padua UniversityAustria: BattenfeldGermany: BASF, Arburg USA: Pennsylvania University, Small Precision Tools

Key Findings

• In the Veneto and elsewhere in Italy the business landscape is primarily made up of small to medium sized firms. In this respect, Italy is similar to Australia and as such provides a valuable model for comparison.

• Industry assistance by government in Italy is apparently targeted to support innovation and technology transfer.

• In each of the three universities where ground-breaking research is being carried out in Singapore, Italy and the USA, financing is provided mainly by industry, with minimal contributions by government. The research in each case was therefore predominantly commercial in nature.

• Italian culture values industry associations more highly than in Australia. Italians demonstrate this by resourcing and supporting their professional associations well and then in turn, the industry associations exert significant influence on government policy and on academic priorities.

• Small, high value added items can be delivered quickly and cost effectively to any destination serviced by in international airport.

• A research priority in each of the universities and in the research labs of the supplier companies was miniaturization. This trend is in response to the recent growth of the micro-technology industry.

• Experts in the USA indicated that there are still backyarders and micro sized players, and that indicates that the industry is in an early stage of development with generous margins.

Maximising the outcomes:

It is essential that the message that PIM is feasible and achievable must get through to Australian manufacturers. Design guides for PIM need to be communicated along with potential cost savings and other benefits. Core to ensuring this occurs is engagement within the tertiary and higher education sector. Engineering students at TAFE colleges and universities are the first groups who need to hear about these benefits and the feasibility of PIM. The TAFE engineering teachers convention would be an appropriate occasion to make a presentation on the technology and there would likely be a higher education equivalent where a similar presentation could be made to a gathering of engineering lecturers.

Furthermore, the three universities visited were involved in commercial research projects in order to survive. TAFE colleges are ideally placed to participate in this kind of commercial development or technology diffusion projects and to benefit from private sector funding, professional development for teachers and project learning opportunities for students. Where necessary the facilities and capabilities of higher education institutions can be engaged in dual sector projects.

For example, as mentioned in the following report, in the Galileo Science and Technology Park, there are four major parts; one focusing on research and innovation, the second on design and new materials, the third on quality and certification and the fourth on incubating new enterprises. All four services in one place help reduce the costs, the regulatory burdens and the practical difficulties of developing and bringing innovative products to market in Europe. A similar service could operate in Australia. In fact the TAFE colleges are natural concentrations of all of these skills and more. A shop front presented as a technology park backed by all the resources of a TAFE college would be an innovation driver and would help business engage with TAFE.

In addition to the above, following an overview of the fellowship experience, a comprehensive series of recommendations are made to Government, Industry, and the Business sector, Professional Associations, Education and Training Providers, our Community and the ISS Institute.

Executive Summary

Table of Contents

1 1. Acknowledgements

1 1.1 Awarding Body - International Specialised Skills Institute (ISS Institute)

2 1.2 Fellowship Sponsors

2 1.3 Fellowship Supporters

3 1.4 About the Fellow

4 2. The Fellowship Program

4 2.1 Aim of the Fellowship

5 2.2 The Skills / Knowledge Gaps

7 2.3 Education and Training Currently Available

8 3. The Australian Context

9 3.1 Peak Organisations and Key Representatives

10 4. International Context

10 4.1 Program Content

19 5. Findings

19 5.1 Key Findings

19 5.2 Options

21 6. Recommendations

21 6.1 Government

22 6.2 Industry

22 6.3 Business

23 6.4 Professional Associations

24 6.5 Education and Training

25 6.6 Community

25 6.7 Ways in which ISS can be Involved

25 6.8 Knowledge Transfer – Applying the Outcomes

26 6.9 Further Skill Gaps

27 References

28 Attachments

11. Acknowledgements

I would like to thank the following individuals and organisations that gave generously of their time and their expertise to assist, advise and guide me throughout the Fellowship program.

1.1 Awarding Body - International Specialised Skills Institute

(ISS Institute)We know that Australia’s economic future is reliant upon high level skills and knowledge, underpinned by design and innovation.

Since 1989 International Specialised Skills Institute Inc (ISS Institute), an independent, national organisation, has provided opportunities for Australian industry and commerce to gain best-in-the-world skills and experience in traditional and leading-edge technology, design, innovation and management.

Carolynne Bourne AM, CEO of ISS Institute, uses her formula to illustrate the links, skills + knowledge + good design + innovation + communication = competitive edge • good business

Based on ISS Institute’s initial market research in 1990, an important category emerged: that of ‘skill deficiency’.

Skill deficiency is where a demand for labour has not been recognised and where accredited courses are not available through Australian higher education institutions. This demand is met where skills and knowledge are acquired on the job, gleaned from published material, or from working and/or study overseas. This is the key area targeted by ISS Institute.

Other ISS definitions:

• Skill shortage is when there is an unmet and recognised demand for labour.

• Innovation Creating and meeting new needs with new technical and design styles. [New realities of lifestyle.]

• Design is problem solving, from concept to production through to recycling. Design involves every aspect from the way the receptionist answers the phone, when invoices are sent out, where a machine sits on the factory floor, what trees are grown in the forest suitable for furniture or flooring, to whether the product is orange or blue, round or square, flat packed for export, displayed in a retail outlet and the market research to target customers’ needs and wants - creating products or services.

Overseas Skill Acquisition Plan (Fellowship Program)Skill deficiencies are filled by building global partnerships through our Overseas Skill Acquisition Plan - Fellowship Program. Australian Fellows travel overseas, or overseas Fellows travel to Australia.

Upon their return to Australia, Fellows pass on what they have learnt through education and training activities such as workshops, conferences, lectures, forums, seminars and events developed and implemented by ISS Institute, therein ensuring that for each Fellowship many benefit - the multiplier effect.

ISS undertakes research, marketing and advocacy.

The findings from the Fellows’ reports and those acquired through our research and education and training activities are made available to firms, industry, commerce, learning institutions and public authorities through ISS Institute’s consultancy services – again, the multiplier effect.

21. Acknowledgements

ISS Institute operations are directed towards bringing skills (traditional and leading-edge technologies) and knowledge to Australian industries, education and government and, in turn, the community in general - new ways of thinking, new ways of working so as to create innovative products and services for local and global markets.

Our holistic approach takes us to working across occupation and industry sectors and building bridges along the way. The result has been highly effective in the creation of new business, the development of existing business and the return of lost skills and knowledge to our workforce, thus creating jobs - whereby individuals gain; industry and business gain; the Australian community gains economically, educationally and culturally.

ISS Institute Suite 101, 685 Burke Rd, Camberwell 3124, AUSTRALIA

T 61 3 9882 0055 F 61 3 9882 9866 E [email protected] www.issinstitute.org.au

1.2 Fellowship Sponsors I would like to thank Carolynne Bourne AM and Jeanette McWhinney for their encouragement and coaching throughout the journey, both before and after the study tour.

I would also like to thank the Office of Training and Tertiary Education (OTTE), sponsor of the ISS Institute Italy/Veneto Fellowship.

The Victorian Government’s Office of Training and Tertiary Education (OTTE) is responsible for the administration and coordination of programs for the provision of training and further education, adult community education and employment services in Victoria and is a valued sponsor of the ISS Institute. I would like to thank the OTTE for providing funding support for this fellowship.

In addition, I would like to acknowledge the support of Swinburne University of Technology, TAFE Division.

Swinburne University, TAFE Division:• John Cawley, Manager of the Centre for New Manufacturing and ISS Institute Fellow

• Carlo De Martinis, Director of the School of Engineering

• Alistair Crozier, Director, TAFE Division

1.3 Fellowship SupportersIn Australia • Ceramet Technologies - Egon Vetter, Business Development

• Ceramic Oxide Fabricators - Alan Walker, Manager

• The Australasian Ceramic Society - Nigel Stone, President

• The Victorian Centre for Advanced Materials Manufacture - Brad Dunstan, CEO

In Singapore• Singapore Institute of Manufacturing Technology - Li Quingfa

In Italy • Veneto Innovazione - Enzo Moi and Marco Gorini

• Assindustria Rovigo - Andrea Busato, Allessandra Merlante, and Franco Gallato

• Padua University - Giovanni Lucchetta

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In Austria• Battenfeld - Christian Gornik

In Germany• BASF - Arnd Thom and Alessandro Pistillo

• Arburg - Marko Maetzig

In the USA• Pennsylvania University - Don Heaney

• Small Precision Tools - Travis Ayers

1.4 About the FellowName Arnold Rowntree

Contact Details Centre for New Manufacturing Swinburne University, TAFE John Street, Hawthorn 3122 AUSTRALIA

T 61 3 9214 8918 F 61 3 9819 0218 E [email protected]

Qualifications Certificate of Applied Science (Ceramics), Caulfield Institute of Technology, 1984

Diploma of Engineering Technology, Swinburne, 2003

Certificate IV in Assessment & Workplace Training, Box Hill Institute, 2004

Graduate Certificate in Plastic Tool Design, Kangan Batman TAFE, Currently completing

Memberships The Australasian Ceramic Society

Until recent years, Rowntree worked primarily in the ceramic industry. Rowntree has ten years experience as a self-employed potter and small ceramic manufacturer. In 1995 he joined Decoramics Pty Ltd and was a branch manager for seven years. In 2003 he retrained and became a TAFE teacher specialising in 3D Mechanical CAD. Additionally Rowntree teaches Maths, Materials Science and Computer Packages in Engineering. Currently he is exploring the use of product design simulation software in technician level training.

Rowntree recently became attached to the Centre for New Manufacturing at Swinburne University where, as well as teaching, he has become involved in several projects including the formation of ATTCA, (the Advanced Technologies Training Capability Alliance). ATTCA is a state wide training network which concerns itself with developing innovative training in areas such as competitive or ‘lean’ manufacturing and with emerging technology industries such as the nano technology industry.

Rowntree built a house in the Otways South West of Melbourne where he lives with his wife and children and enjoys gardening, bonsai, ikebana and pistol shooting.

1. Acknowledgements

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The ISS Institute Italy/Veneto Fellowship is awarded for the purpose of allowing the recipient to undertake an overseas study program that specifically includes the Veneto region of Italy. Other destinations were two universities, one each in Singapore and the USA, a raw materials supplier in Germany, injection moulding machine builders in Austria and Germany and a PIM parts producer in the USA.

2.1 Aim of the FellowshipThe aim of this fellowship is to identify and acquire the skills and knowledge critical to enable the greater take up and employment of Powder Injection Moulding technology in Australia to satisfy existing global demand and potential local demand.

2. The Fellowship Program

A Short Description of PIM:Powder injection moulding is a manufacturing process whereby precise metal or ceramic parts are produced. A metal or ceramic powder is mixed with either wax or a polymer so that the powder can be injection moulded. The moulded parts are treated by a chemical or thermal procedure to remove the polymer or wax and then the parts are sintered at high temperatures in a furnace. The resulting parts have exceptional properties, are well finished and precise.

The market for PIM parts has been growing quickly around the world at between 10 and 30 per cent per annum. This has been the case for two decades indicating that the growth of the industry has steady momentum.

Applications are many and varied including automotive, aerospace, defence, fashion, electronics, bio medical and anywhere high performance parts are required. Consumers may never hear about this process but will benefit from improved consumer products. Manufacturers can avail themselves of economical and higher quality parts for their products by incorporating this technology.

For additional information as to PIM, see attachments6.

Specific areas of study and development for the current studyBased on the target destinations and in order to derive maximum benefit from the study, the following areas have been identified for consideration:

Collection of PIM parts displayed at the BASF stand, AUSPLAS 2005, Melbourne Exhibition Centre

A Collection of PIM parts


• Material selection procedure for specific parts

• Observation of the equipment used and the process for feedstock formulation

• Learn about injection moulding machine characteristics and configuration for PIM applications

• Learn how the PIM process affects part design

• Learn the differences between PIM and plastic mould design

• Observe debinding equipment in operation and the processing steps

• Understand sintering equipment and associated processing

• Discussion of toolmaking education and skill availability

• Observe the layout and equipment involved in a research facility setup

Ongoing areas for development:• Understanding of market intelligence and the state of the industry in Europe and the USA

• Establishment of contacts for future research collaboration in universities and businesses

• Investigation of the background and processes for the initiation of a Technology Park

2.2 The Skills / Knowledge GapsPowder Injection Moulding is an established manufacturing process in Europe, the USA and Asia, but only a few companies in Australia employ PIM perhaps due to, among other things; a lack of training.

According to Dr Randall German1, a leading authority on the process, it is growing at a compound rate of 32% per year in the US, Asia and Europe and is an important manufacturing process for the twenty-first century. It is important in the production of complex, small and micro components especially when an item needs to have advanced properties.

A wide range of industries are using parts made by the PIM process in other countries and in Australia feedstock vendors (for example BASF) report that there is growing interest at local trade exhibitions when metal and ceramic injection moulded samples are displayed.

The early development of the technology has been by high-level academic research but the materials processing skills needed to support the process in operation are the preserve of TAFE (Technical And Further Education), as is frequently the case in the design of components and tooling. Proprietary feed stocks can be sourced allowing attention to be focussed on the processing skills rather than on the science.

The operation of the injection-moulding machine has considerations unique to the process although they are similar to plastic injection moulding. The operation of the debinding oven and sintering furnace require specific understanding. In most cases robotic arms are needed to unload fragile green parts from the injection-moulding machine during each cycle.

The tooling for PIM can utilise multiple cavities, sliding cores and other techniques common to plastic injection moulding tooling. Research has indicated that the skills available in the Australian toolmaking industry are adaptable to PIM tool design and production.

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Knowledge areas relevant to the process are listed below and these informed which overseas researchers and their organisations would be approached as part of the Fellowship Program.

• Conducting Moulding Trials (BASF)

• Conducting Debinding Trials (BASF)

• Conducting Sintering Trials (BASF)

• Furnace design and optimisation (this is left to furnace manufacturers)

• Automation setup and operation (Arburg, Battenfeld)

• Material Selection (BASF)

• Feedstock Formulation (SIMtech, CISP, BASF)

• Feedstock Preparation (CISP, BASF)

• Mould Dimensioning and Design (Accomplished through third party tooling companies)

• Part Design (CISP, BASF)

• Mould Shrinkage Calculations (BASF)

• Gate Selection Options (BASF)

• CAD software choice (Not covered)

• CAM software choice (Not covered)

• CAE software choice (SIMTech)

• R&D Pilot plant equipment requirements (SIMTech)

• Participation in international projects (Various)

• Market intelligence (Through conversation)

• Training skill sets (SPT)


Fashion industry parts Ceramic parts as moulded and finished showing shrinkage.

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2.3 Education and Training Currently Available The Metal and Engineering Training Package (MEM05) is relevant to Powder Injection Moulding and the trades people who will be affected are toolmakers who will enrol in the:

• Certificate III in Engineering – Mechanical trade

• Certificate IV in Engineering Technology (Post Trade).

It is not necessary to modify any units in these courses since the moulds for powder injection moulding are not substantially different to moulds designed for plastic injection moulding.

Whilst the main components of these courses are relevant to the generic aspects related to moulds designed for plastic injection moulding, the particular skills and underpinning knowledge in the techniques and applications for PIM will need to be included.

Toolmakers enrol in local TAFE courses for example RMIT, Swinburne and Chisholm Institutes in Melbourne.

Similarly Tool Design is a relevant area and a Graduate Certificate in Plastic Tool Design is available at Kangan Batman TAFE in Melbourne. An internet search has revealed that this may be the only course of its kind in Australia and the fellow is currently completing it. Again, the course seems not to require significant changes to accommodate PIM tool design.

The Plastics Rubber and Cablemaking Training Package (PMB01) covers the plastics injection moulding industry and the skills involved with the operation of injection moulding machines.

The Certificate II in Plastics is a course offered to machine operators in the plastics industry and Bill Rees, Manager of Kangan Batman’s Polymer Engineering Centre informs Rowntree that this course is designed to be contextualized (in practice this occurs more often than not) and PIM processing can be adequately accommodated without changes to the competency documentation.

One training course that would be appropriate for teaching more specific PIM knowledge and skills is the Advanced Diploma in Engineering Technology and particularly the Manufacturing Processes and Materials Science units. Please see section 6 Recommendations.


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Powder Injection Moulding PIM is a growing technology widely practised around the world over the past three decades but in Australia only by a very few companies. Industry estimates of the annual growth of PIM internationally over the last decade are up to 30% according to Dr Randall German, recognised authority and author on PIM. The growth is expected to continue in the 21st century.

With regard to Australia:

• Skills training in this field is unavailable at any TAFE college or university and as such this technology was an ideal skills gap for an ISS Institute/Italy (Veneto) Fellowship to investigate and develop.

• In the case of small, high value added components, export markets can be more important for Australian producers than local markets. Small parts don’t occupy much volume and in these cases the tyranny of distance is broken since a company’s entire production for three months might fit into a small package that can be airmailed to an overseas customer quickly and cheaply.

• In recent years manufacturing firms increasingly participate in “distributed design” projects and also in projects where the design occurs in one country while the manufacturing is done in another. Australian designers with sufficient knowledge could participate in international teams.

• Australian companies employing the technology could benefit from the availability of training. At present they must train staff internally or bring skilled people from overseas. Consequently the development of the capability in Australia is hampered.

• Acquiring the capability to process advanced materials is a stepping-stone to developing industrial capabilities to process advanced materials by other more demanding manufacturing processes at the small and micro scale.

• Small and micro toolmaking is a suitable up-skilling and redeployment of plastic injection toolmakers unemployed or underemployed due to the decline in the automotive industry.

• The economics of the PIM process suit some components which should be treated as candidates5 for PIM projects. If Australian firms use less efficient manufacturing processes for those same components it means we are that much less competitive compared with the increasing number of countries where PIM is utilised.

• Some Australian plastic manufacturers point to an over-capacity in injection moulding due to the decline in the automotive industry. The only growth is in specialist areas of which PIM could be an example. Some Australian injection moulders would benefit by investigating PIM, provided they have access to the necessary skills.

3. The Australian Context

Ideal geometry makes this metal part a suitable candidate for PIM

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3.1 Peak Organisations and Key Representatives The Australasian Ceramic Society (ACS) is a national body for manufacturers and academics as well as artists and is representative of the advanced ceramics industry and the clay products industry. The society is also affiliated with a metal materials association. The members of the ACS could benefit from an understanding of PIM opportunities, especially those members in manufacturing. The growth of PIM around the world indicates that opportunities will exist in Australia too. The local investment casting industry is unchallenged by any local PIM producers and many inefficient traditional suppliers will be vulnerable to any ACS members armed with a PIM capability.

Australian toolmakers, tool designers and product design consultancies could benefit from locally available skills training in PIM. If local businesses take up the technology and win a proportion of the large and growing PIM markets they can be supported by the availability of local training.

TAFE colleges and higher education facilities would benefit from a proposed PIM research and development program that entails the ability to process advanced materials by PIM. This processing capability opens the door to the small, micro and nano-technology sectors as a gateway or enabling technology. Some of the people visited were interested in future collaboration. These contacts have valuable potential.

3. The Australian Context

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The overseas program was designed to explore the identified skills and knowledge gaps and to obtain the information necessary to return to Australia equipped with the knowledge and ideas essential to ensuring enhanced teaching practices and content delivery. Offering effective experiences and opportunities for others to maximize their learning will be essential to promoting and improving the overall acceptance of Powder Injection Moulding in this country.

4.1 Program ContentThe following site visits and meetings proved to be most significant in providing information and inspiration:

SingaporeThe first stop was in Singapore to meet the Chief Scientist at the Singapore Institute of Manufacturing Technology, Dr Li Quingfa who has published many research papers on PIM. Dr Li is regarded as a leader in the field and is widely known even outside PIM. Dr Li runs a PIM Lab and is currently working on Micro PIM.

In discussing the limits of current research, Dr Li identified that parts as small as 12 milligrams have been achieved five or six years ago, but anything smaller is not yet commercialised. He is currently investigating transparency for optical applications now that translucency is commercially established.

Dr Li’s department at SIM tech is primarily funded by local industry and his lab has enough equipment to do work on several variations of the debinding and sintering stages of the PIM process.

Two key observations noted in discussions with Dr Li were as follows:

• Plastic moulders rarely make a successful transition to PIM because it’s the metallurgical experience focusing on the microstructure that makes the difference.

• The emphasis on PIM being a ‘net-shape’ process is oversold. Nearly all parts required at least some secondary operations such as polishing or lapping for final tolerances.

A significant proportion of the work being undertaken by the Singapore Institute of Manufacturing Technology involves the development of new materials. This factor identifies the beauty of PIM in so far that a material can be tailor made for an application. Mechanical, chemical, electrical, electromagnetic and even optical properties can be supplied for particular applications. PIM has made inroads into the industries serviced by investment casting, including aerospace, firearms, bio-medical and transport.

Veneto: a case study in collaborationThe Veneto region is situated in the very north-eastern region of Italy. The principal city is Venice but it also includes Verona, Vicenza, Padua and Treviso. The region’s population numbers 4.51 million, which accounts for 7.7% of the total Italian population. Key sectors and industrial clusters in the area include textiles and clothing, wood and furniture, footwear, electro-mechanics, eyeglasses and metal mechanics.

Veneto is a fascinating location in terms of demonstrating what can be achieved when bodies work together to provide financial backing, support and commitment to a shared vision. Veneto provides a rich case study with its effective network of technology parks

4. International Context

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collaborating to ensure the success and promotion of research, innovation and design. In terms of profile Veneto is a region of excellence for innovative start-ups.

As identified on the Paxis website3, ‘the aims for the Veneto region in terms of development of the innovation and start-up industry is firstly to promote and support work being undertaken in the fields of applied research and innovation. Secondly the region seeks to foster co-operation between small and medium enterprises (SMEs) and the centres of research and innovation and the universities. By achieving this, research projects and innovation initiatives can be co-ordinated effectively, employing the services of all relevant parties to maximum efficiency and ensuring a greater degree of continuity; from the infancy stages of research to the final marketing and selling of a product or service. In addition, by forming SMEs into clusters of similar technologies and know-how, it is hoped, through the pooling of knowledge, that synergistic results will emerge.

The financial sources that are backing the initiatives for promoting innovation and new start-up enterprises are threefold. The Veneto Regional Authority provide 51% of the capital share, the Veneto Union of the Chambers of Commerce 13% and the 4 major regional enterprise federations (comprised of industrialists and craftsmen) 36%. Veneto has 4 universities, one each in Padua and Verona and two in Venice. Though the Veneto universities play very active roles within the activities of the companies, they hold no capital share.

The science and technology parks in the area of Veneto cater for and bring together the hi-tech companies and start-ups in the local area and bring in companies from the rest of Italy and the Global economy. The three principal parks are:

• VEGA – Venice science and technology park

• Galileo – Padua science and technology park

• STAR – Verona science park

All the science and technology parks and regional science and technology structures are connected together through the NEST (Network for Science and Technology) programme. As well as the three main science parks there are also a serious of “nodes” throughout the region, districts that demonstrate a strong specialisation in a particular sector.

The Veneto Innovazione company promotes and holds shares in various NEST structures in order to maintain their network efficiency.

The Veneto Regional Authority confirmed the importance and significance of having a regional network of innovative services. By recognising this in a regional act, official support and promotion was given to the creation of a multipolar science and technology park in the Veneto region.

Source: http://cordis.europa.eu/paxis/src/veneto_region.htm

Site visits:1) Padua University: Polymer Research FacilityWhilst the Veneto component of the Fellowship Program provided the models for applying the technology through skills in ways of working along the Supply/Value Chain (eg bringing new technologies to fruition such as at Vega Park), the Polymer Research facility at Padua University has significant injection moulding research. A visit was arranged to meet with Mr Giovanni Luccheta and Professor Bariani, who work in areas of injection moulding research,


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a field related to powder injection moulding. Key areas of current research include metrology and the new variations on plastic injection moulding technology.

A successful outcome of the visit occurred with Rowntree facilitating a connection for Mr Luccheta some months after the fellowship tour. Rowntree was able to provide details of a professor in another Italian region who had co-authored research papers on PIM with an American researcher, Dr Don Heaney. This connection has the capacity to foster collaborative exchange and knowledge transfer regarding PIM.

A key outcome of the visit with significant implications for Rowntree was learning of an international association of manufacturing research academics known as CIRP4 (from the French acronym of College International pour la Recherche en Productique). CIRP brings together scientific methods of the research community to industrial manufacturing technology. CIRP offers world leadership in research on advanced manufacturing technologies with over 550 members from 40 industrialized countries. CIRP aims to:

• promote research and development of manufacturing technology, including design, optimization, control and management of processes, machines and systems.

• promote cooperative research among its members and create opportunities for informal contacts among researchers from academia and industry.

One of the key activities of CIRP is to disseminate the findings of manufacturing research across the European Union. Rowntree has identified Australian representatives within the organisation and this will provide a valuable source of information on current advances and trends for Rowntree’s work with the Centre for New Manufacturing at Swinburne University of Technology.

Rowntree is looking forward to maintaining and further developing his contact with Padua University.

2) Industry Association presentation: RovigoRowntree met with the director of Assindustria Rovigo, Franco Gallato, a chemical engineer, and one of his colleagues from the association, Alessandra Merlante. This association has input into the research undertaken by Professor Bariani, Polymer Research facility at Padua University.

3) Galileo Science and Technology ParkGalileo Science and Technology Park in the Veneto town of Padua exists to provide a one-stop shop for Italian businesses and entrepreneurs.

The Galileo Science and Technology Park (PST) is an association joined by the Chambers of Commerce of Padua, Treviso, Vicenza and Belluno, the University of Padua, the Commune and the Province of Padua, the Fondazione Cassa di Risparmio di Padova e Rovigo and the Veneto Innovazione.

The mission of the Park is to strengthen the competitive capacity of businesses through the realisation of activities aimed at diffusing technology and applied research results.

The Park’s activities stand out in the areas of innovation and research (meeting point between demand and supply of technological innovation), design and new materials (creativity for product innovation), quality and certification (interface between businesses and laboratories) and start-up businesses (an incubator of new businesses). These activities are performed in close collaboration with the University of Padua the Research Centres,


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and the Category Associations present in the region. Furthermore, the service that the Park places at the disposal with Ma Tech, allows businesses to be kept updated regarding innovative materials at an international level and provides research and consulting services.

Source: www.galileopark.it

Ma Tech, specializes in materials selection. This in itself is not new, there are other services like Ma Tech with large databases with many thousands of records of properties, prices and sourcing information, but at Ma Tech samples are displayed in an attractive showroom where visitors can handle a wide range of new and impressive materials. Ma Tech activities and the innovative materials database can be viewed in the site: www.matech.it. Go to: www.galileopark.it

4) SIDA visit was also undertaken to the Scuola Italiana Design School (SID); an industrial design school taking students for vocational courses and providing consulting services to local business.

SID’s mission is targeted around 3 main aims:

1. Contributing to the cultural, professional and relational growth of young creative designers, ready to enter the world of work:

• able to create new ideas utilizing the SID Creative Method which has been developed with great attention to the most updated international methods

• able to develop product design projects, with skills extended to visual, packaging and web design

• able to communicate his/her own projects with the most updated procedures

• with professional skills, constantly in touch with the Enterprises

2. Promoting the culture and knowledge of creative design by firms and their consumers

3. Providing design services firms aimed at:

• the product innovation, with skills extended to visual, packaging and web design

• the selection of young designers.

The School’s website identifies that ‘thanks to these guidelines Scuola Italiana Design®’ has become a reference industrial design school in Italy for the training of young designers and a centre of creativity for the product innovation.

The distinguishing mark of Scuola Italiana Design is the close relationship between the School and firms. The educational experience prepares students for the professional relationship through a direct contact with businesses, its needs and its working methods. The School recognises that creativity is a primary value of design; for this reason it prepares its students for problem solving, paying great attention to the analysis and the interpretation of the needs that the product is meant to fulfil.

Of particular interest is information gathered by Rowntree regarding a consulting project for a local furniture business which involved teaching staff and students facilitating opportunities for students to participate in projects in order to satisfy course requirements. Fields of application included graphics and web design as well as product design.

http://www.scuolaitalianadesign.com/ (select English version)


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Two further sites of interest that contribute to Veneto’s richness as a case study include VEGA Park and the STAR Science Park:

VEGA ParkVEGA Park is a city of technology and innovation which acts as a bridge between universities, research centres of excellence and the production sector to facilitate the competitiveness of locally-based companies in national and international markets. VEGA is characteristic of countries that have made the important business of technology application a fundamental part of their economic system. VEGA identifies, promotes and carries out projects that aim to bring improvement and innovation to production cycles and to the quality and range of products produced by locally-based small to medium enterprises.

VEGA has established a network of interconnected lab’s which between them link the most important advanced specialised research organisations based in the Venice area, which operate in the following fields: materials, restoration and environment. VEGA houses approximately one hundred highly specialised companies which enjoy opportunities for creating partnerships and synergies on joint projects. Additionally, VEGA provides access to regional and community funds and a wealth of state-of-the-art facilities. VEGA offers an effective model to explore in terms of thinking about possibilities for making connections within the Australian context.

See http://www.vegapark.ve.it

STAR Science ParkSTAR Science Park has been operating since the beginning of 2001 and supports research development and spreads innovation by encouraging entrepreneurship and creating ties between research and industry. The Science Park is therefore regarded an innovation service centre which links the industry with the world of research. It promotes “dialogue” between innovation supply and demand through putting together the various interests and directing common efforts towards clear and measurable objectives. The park’s activities include applied research and pre-competitive development projects as well as skills’ analyses and technical consultancy. Additionally, the Park offers assistance in obtaining public funding, supports projects of innovation (at regional, national and European level) and provides services related to project management (planning, coordination of operative phases and project financing).

Source: http://www.venetonanotech.it

Veneto as a model: the measure of success An analysis of Veneto and its technological facilities suggests that it offers a successful model for pursuing innovation and technical research and development. The success of the Veneto model can perhaps be measured by a breakdown of the regions profile. The regions employment level is vastly above that of the national average. Unemployment in the Veneto region is only 5.0% compared to a national level of 19.9%. In fact the region has about 10% of the total Italian employed population. In all there are 1.86 million employees in the Veneto region.

The region contains some 450 000 companies, one tenth of all the companies in Italy. On average there is about 1 company for every 10 inhabitants and each of these companies employs on average 4.1 workers (compared to the Italian average of 3.9).

The Veneto region produces 14.5% of all Italian exports and accounts for 33% of the Italian trade balance. In monetary terms exports amount to €30.04 million. Exports from the Veneto region account for 38% of GDP.

Source: http://cordis.europa.eu/paxis/src/veneto_region.htm


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Battenfeldhttp://www.battenfeld.com

Battenfeld, a name well known to people in the plastic injection moulding industry is a supplier of top quality moulding machines. Rowntree met with Dr Christian Gornik at the company’s PIM research laboratory in Kottingsbrunn, Austria. Dr Gornik described in detail the machine features available as options for PIM.

The plastification unit is the main difference between a PIM machine and a plastic one. MIM feedstocks have a high thermal conductivity, between 10 and 100 times that of plastic, and therefore they freeze promptly. This factor increases the need for fast filling of the mould and in cases where the part is long and thin, a hydraulic accumulator is necessary to achieve fast filling. The wear factor for MIM feedstock is comparable to 30% nylon filled plastic.

One of the further options Battenfeld can provide is a pressure transducer on the barrel of the machine to improve process consistency by five times. It is possible to have a transducer present inside the mould itself. This provides even more control over moulding conditions.

Another optional feature is a double pump for parallel movements. A hydraulic accumulator allows for fast action especially useful for thin walled parts.

In the case of CIM (Ceramic Injection Moulding) the machine screw needs to be tungsten carbide, the Battenfeld supplied screw is of fine grain size and even distribution of the tungsten resulting in better resistance to erosion. MIM (Metal Injection Moulding) screws supplied by Battenfeld are through hardened.

It is important to provide a ‘diving’ or ‘extended’ nozzle in the mould design. Opposite the sprue, the undercut device for ensuring that the sprue demoulds with the part needs to have a shallower angle than for plastic otherwise there will be shear. The green PIM part is brittle.

70,000 injection moulding machines are sold worldwide each year, Battenfeld sells 1,000 and of those, 30 - 40 are for PIM.

A factory tour identified some very large and some regular sized machines in assembly, the production of barrels and screws and many large components such as plattens for the bigger machines. These are precise parts. It is apparent that Battenfeld is an exemplar of world class engineering.

A further facility that was of key interest at the Battenfeld factory was the testing room for the Micro System 50, a machine for micro injection moulding, the cabinet housing is a clean room environment in itself. The moulding action is automated, the demoulding is automated as is the vision system controlling the quality of the parts. The part in production at the time of Rowntree’s visit was an optical plastic component. This machine is also suitable for PIM.

BASFhttp://www.basf.corporate.com/

BASF is a large German chemical company which supplies standard plastic feedstock materials for plastic injection moulding and also a range of PIM feedstocks that go by the trade name ‘Catamold’. Mr Arnd Thom, business manager for production and marketing of Catamold hosted a facility visit of the BASF PIM laboratory. It’s here that BASF conduct processing trials and other development work to support their customers.


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Discussion occurred regarding the Catamold range of material feedstocks supplied by BASF and then principles of part design illustrated by particular examples. One was a bicycle click pedal formerly made as an assembly of seven components but now injection moulded in one part. This was not only a saving in manufacturing costs but also an improvement in the quality and reliability of the pedal.

Arnd offered several insights about his work dealing with companies who are potential users of this technology. Those in the fashion industry, for example the makers of sunglasses are interested in parts like hinges and their primary concern is the time to market or speed of development and production. It was noted that companies in the electronics industry (mainly in Asia) are concerned only with low prices, companies involved in defence or military contracts are concerned only with quality. The automotive industry is also concerned with quality but Arnd identified that often price will also persuade them.

The decision as to the suitability of a part for the PIM process comes down to investigating each part in detail. Rules of thumb such as quantity per year, required material properties, complexity of geometry and a part weight limit of 50 grams are a starting point and the part can usually be qualified. The next stage is a tool design and costing exercise.

The chart below compares powder injection moulding with competing manufacturing processes, courtesy BASF.

Rowntree had an opportunity to visit the moulding trials room where a technician demonstrated how a PIM die is set up on an injection moulding machine. The dies for PIM are typically oil heated to around 170 degrees centigrade and the technician varied the temperature, the quantity of feedstock in each shot and the pressure duration for the cycle. Each test injection produced a part and the technician demonstrated how each of the parameters affected the quality of the part being trailed.

Arnd loaded the trial parts into the debinding oven and Rowntree was able to see the transition from ‘green’ moulded parts to debound ‘brown’ parts. All the products in the Catamold range of feedstocks are debound by a catalytic process and the active chemical is nitric acid. Time was also spent investigating the design of the debinding oven together with the health and safety features associated with its operation.


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On day two of the visit, Rowntree looked at the sintering furnace supplied by Elnik. The Elnik furnaces are reputed to be the ‘Rolls Royce’ of furnaces, all the lining and shelves are made of Molybdenum and the atmosphere inside during operation is either vacuum, hydrogen or argon depending on the material being processed.

The BASF visit was very informative and was effective in meeting a number of Fellowship aims and objectives. This visit has been instrumental to the fellowship findings and informs several of the recommendations that follow later in the report.

ArburgArburg in Lossburg, Germany is another world leader in supplying quality injection moulding machines. Mr Marko Maetzig hosted the Fellowship visit and provided a tour of the PIM laboratory and factory.

Arburg and Battenfeld are competitors in building machines for injection moulding and are widely recognised as quality suppliers. In terms of the differences between the two companies, an analogy can be drawn between Ford and Holden in Australia, personal choice but very little substantial difference. Some companies however have a preference.

Marko described the features that make a PIM machine unique and identified differences in approach. Rather than offer a package of features, they recommend some. Among them are; closed loop control to allow for higher dynamics. A position regulator is like an effective brake to complement the acceleration performance. Marko also provided information on several machine screws and described their functions and differences.

It was identified that Arburg utilise a test die which can take mould inserts for trial runs. When discussing choice of a toolmaker or mouldmaker, Marko noted that you can work with any mouldmaker but the ones that are best to work with are those who can absorb new ideas and break out of the traditional methods. Plastics moulds have been made the same way for so long that people tend to get comfortable in their ways. The material feedstocks have different viscosity and especially they have higher thermal conductivity.

Marko hosted a tour of the factory and it was immediately apparent that Arburg use “Lean” manufacturing techniques in the way Toyota is “lean”. Despite being a heavy engineering factory it is as clean as can be and very well ordered.

In response to his visit, Rowntree received a collection of example parts to use as object lessons with his students.


A PIM part formerly investment cast. Note the tiny holes which used to be a secondary operation, now moulded in.

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Pennsylvania State UniversityDr Donald Heaney is research director of the Centre for Innovative Sintered Products at Pennsylvania State University. The CISP was founded by Dr Randall German, the author of several popular books on the subject of PIM.

Dr Heaney provided a number of academic papers and magazine articles on PIM and spent time discussing applications and research followed by a tour of the facilities. Like Dr Li he has been working on micro featured PIM parts for bio-medical applications.

Another similarity with Dr Li’s work is the fact that the research Don carries out attracts no government funding and consequently everything has to have immediate commercial value. The CISP was the largest and best equipped of all the facilities observed during the tour although it was not quite as well utilized as some of the others.

While visiting the lab, Rowntree observed some students who were working on a custom feedstock of a metal alloy. They were having trouble with the equipment and Dr Heaney helped them solve the problem. The solution involved dismantling the machine, cleaning, reassembling and testing the output. This experience was only a frustration for Dr Heaney and the students but it was an opportunity for Rowntree to ‘get his hands dirty’ and really learn about feedstock formulation.

Dr Heaney had a wide range of PIM parts on hand and we discussed many of them. An interesting one was a rocket cone from a missile made of a refractory and very hard alloy.

Small Precision ToolsThe final visit was to Small Precision Tools where Rowntree met with Mr Travis Ayers, Plant Manager, Petaluma, California, USA.

It’s unusual for a business to welcome someone on a fellowship tour who is learning about technology in order to benefit the industry in the sending country but Ayers was generous and open. Small Precision Tools are engaged in technological achievements equal to any Rowntree saw in other countries, but Ayers was kind enough to spend time providing a tour of the Petaluma plant and introduce Rowntree to staff.

SPT employs around a hundred staff in Petaluma and about a thousand around the world. Their headquarters is in Switzerland and they are known for precision ceramic injection moulding.

One of the parts in regular production is a fine example of precision engineering. A capillary with a hole measuring 25 microns is being made of high purity alumina ceramic. In-house experts have custom built quality control equipment to keep manufacturing tolerances within one or two microns. The ability to consistently produce quality parts at this scale indicates disciplined staff in control of process variables.

In discussion with Ayers, Rowntree asked Ayers to identify ‘what and how’ his ideal employee would be educated? Ayers replied that “he would have a degree in process engineering or perhaps manufacturing engineering, a thorough understanding of the physics and chemistry of injection moulding and preferably powder injection moulding. He would prefer people to have a good practical ability with machine tools as well as sound engineering knowledge”. Ayers acknowledged that this was a ‘tall order’ but Rowntree had asked for the ideal.


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The adoption of PIM technology has been slow in Australia because local design engineers only know how to design for the traditional methods of manufacture and don’t see themselves as players in global markets. This lack of knowledge and ‘know-how’ locks Australian firms out of competitive capabilities and commercial opportunities.

Only one firm, Ceramet Technologies based in Ballarat, is growing quickly by aggressively pursuing PIM technology and exporting the vast majority of its product.

5.1 Key Findings• The Italian business landscape is primarily made up of small to medium sized firms.

In this respect, Italy is similar to Australia and as such provides a valuable model for business development including bringing research and development to fruition.

• Industry assistance by government in Italy is apparently targeted to support innovation and technology transfer.

• In each of the three universities where ground-breaking research is being carried out in Singapore, Italy and the USA, financing is provided mainly by industry, with minimal contributions by government. The research in each case was therefore, predominantly commercial in nature.

• Italian culture values industry associations more highly than in Australia. Italians demonstrate this by resourcing and supporting their professional associations well and then in turn, the industry associations exert significant influence on government policy and on academic priorities.

• Small, high value added items can be delivered quickly and cost effectively to any destination serviced by in international airport.

• A research priority in each of the universities and in the research labs of the supplier companies was miniaturization. This trend is in response to the recent growth of the micro-technology industry.

• Experts in the USA indicated that there are still backyarders and micro sized players, and that indicates that the industry is in an early stage of development with generous margins.

5.2 OptionsIt is essential that the message that PIM is feasible and achievable must get through to Australian manufacturers.

Design guides for PIM need to be communicated along with potential cost savings and other benefits.

Engineering students at TAFE colleges and universities are the first groups who need to hear about these benefits and the feasibility of PIM. The TAFE engineering teachers convention is an appropriate avenue to present the nature and scope of PIM technology and the findings of this report as well as through professional associations such as Engineering Australia.

The report’s findings will also be disseminated to the Victorian TAFE Engineering Senate, Australian chapter which is allied to CIRP (a French acronym), a world wide organisation of manufacturing technology academics in higher education.

5. Findings

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In addition, the three universities visited were involved in commercial research projects in order to survive. TAFE colleges are ideally placed to participate in this kind of research and to benefit from private sector funding, professional development for teachers and project learning opportunities for students. Where necessary the facilities and capabilities of higher education institutions can be engaged in dual sector projects.

For example, as mentioned, in the Galileo Science and Technology Park, there are four major parts; one focusing on research and innovation, the second on design and new materials, the third on quality and certification and the fourth on incubating new enterprises. All four services in one place help reduce the costs, the regulatory burdens and the practical difficulties of developing and bringing innovative products to market in Europe.

A similar service could operate in Australia. In fact, the TAFE colleges are natural concentrations of all of these skills and more. A shop front presented as a technology park backed by all the resources of a TAFE college would be an innovation driver and would help business engage with TAFE.

A firearm component, as moulded (right) and finished with consequent shrinkage (left).

5. Findings

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The following are recommendations to Government, Industry, the Business sector, Professional Associations, Education and Training Providers, our Community and the ISS Institute.

6.1 GovernmentFinancial assistance to industry for the purpose of supporting the adoption of PIM technology would be best targeted to programs involving innovation and technology transfer if the Italian experience is any guide. This can be channelled through educational institutions, with stipulations encouraging closer industry engagement. It should be borne in mind that the research facilities Rowntree visited were doing well through mainly private sector funding.

Federal Government Higher education in Australia is funded by the Commonwealth Government and through individual university endeavours such as working with industry and fee-for-service activities. There are two kinds of academic research: scientific and commercial. Scientific research is the expansion of knowledge whether or not there is a technological application, and commercial research is intended to realize a business benefit.

The universities visited were undertaking commercial research for specific companies. The same situation can be fostered in Australia by directing researchers to seek partnerships with business and by redirecting incentives to reward those who do. This is not to lessen the significance of scientific research, but to highlight the need for and benefits of commercial research that were witnessed elsewhere. Perhaps the lack of PIM research in Australia is due to a lack of applied research in general. This needs to be investigated.

A planetary gear made of steel

Victorian GovernmentTechnology transfer and the encouragement of innovation through programs such as Galileo Park seem to be ideally suited to TAFE Institutions. In TAFE there are concentrations of knowledge and skills untapped by manufacturers and other businesses.

Funding should be made available to projects in TAFE institutions designed to encourage engagement with business offering multiple services for research and development as well as marketing and all relevant fields of expertise. Teams of TAFE teachers can work on development and product design projects for companies and they can also offer consulting services and industry based on-site training. The current emphasis on industry-led, demand-driven VET should be maintained. In particular, efforts within the Victorian TAFE system to help companies acquire PIM technology should be supported.

6. Recommendations

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Through the Fellowship Program, research, business and training contacts have been made in the Veneto and elsewhere and as such are a valuable knowledge and skill resource which could be further leveraged through further fellowships and joint, collaborative projects.

6.2 Industry • Small and medium sized companies can explore business opportunities in PIM. There

are still small backyard sized operations in the USA comprising only one or two injection moulding machines. This indicates margins are plump.

• Existing injection moulding companies with spare capacity and looking for new business opportunities should investigate small sized components made in unusual materials for companies in Australia and overseas. There is a wide and growing variety of PIM applications5 and the lack of PIM producers in Australia indicates an under supply.

• Small injection-moulded component manufacturers could seek out partnerships with consulting metallurgists and export consultants in order to gain access to the necessary skills and experience to service overseas markets. In Victoria there is now expertise in the TAFE system to support the acquisition of PIM technology. Specialist centres such as The Centre for New Manufacturing at Swinburne can assist in facilitating these partnerships.

• Companies making components by traditional manufacturing processes could re-evaluate their approach in each case in the light of the potential savings available through the PIM process. Again, Swinburne’s Centre for New Manufacturing is able to facilitate this re-evaluation and re-assessment drawing on its contacts with local and overseas specialists.

• The Australian tool making industry could be informed about PIM for the purpose of redeploying spare capacity as the automotive industry declines and for the wider purpose of pursuing a world-wide growth opportunity. All the capabilities newly acquired in the process of employing PIM technology are transferable to other advanced manufacturing technologies.

6.3 Business The rapid growth of PIM around the world (quoted as 32% per annum by Professor Randall German) indicates an under supply, especially in Australia where adoption has been minimal. This should be a signal to entrepreneurs that there is a business opportunity. Also, since PIM parts are high value added and usually of small size, markets are not restricted to local consumers but products can be economically air freighted, meaning markets are global.

The promotion of PIM business must also be targeted to chief engineers and engineering designers, the decision makers in manufacturing companies. Mr Arnd Thom of BASF in Germany described the procedure of sitting down with engineers and working through each individual part, qualifying each according to size, function, material, geometric complexity, quantity required. Those parts remaining as candidates are subjected to further analysis, a tool is designed and simulated for each, and an entire project is mapped and costed. Where suitable benefits are confirmed, a prototype tool is produced and trials are run before scaling up to full production.

6. Recommendations

23

Ceramet Australia could take on the production, depending on capacity constraints, or alternatively, other producers overseas could be engaged while capacity is increased here.

There is a role for Swinburne’s Centre for New Manufacturing in facilitating the interaction between PIM producers whether they are in Australia or overseas. The CNM can develop the qualifying and project assessment skills described above as well as assembling the human resources and tool design skills necessary for a PIM project. This intermediary role fits with the concept of a Skill Ecosystem approach, facilitating commercial projects while building training capacity in TAFE at the same time.

Small companies or startups could consider either PIM manufacturing or acting as an intermediary between existing PIM producer companies and potential consumer companies. Venture capital broker Paul Toohey informed the fellow that Investors require a convincing business plan with several salient features including:

• Presentation of the market and marketability of the product or service.

• The personnel involved in the enterprise; their expertise and experience.

• The nature of the product or service

• The management of the business

• The financial status of the business

• The operations of the business

• The execution of its marketing plan

• Funding requirements

• What is the return on investment sought

• What is the exit strategy

• A risk and mitigants section.

• Consumers – current and future

6.4 Professional Associations The Australasian Ceramic Society can benefit from use of this technology.

Presentations, information session and forums to discuss the PIM process described in Rowntree’s findings, together with the economic thresholds that make it a competitor with the manufacturing processes currently being employed, would assist with the dissemination of information.

The Australasian Ceramic Society has recently become an exclusively online organization with stronger links to other materials society such as a metals society. PIM is a process applicable to ceramics, metals, plastics, composites and combinations of these. A presentation to the members of other materials societies would highlight the business benefits of the PIM process, the design guidelines for parts and the processing parameters for relevant materials. The benefits to each materials society would be the same as for the ACS; an understanding of why PIM is worth investigating.

The Tooling Industry Forum of Australia is a professional association of tool making companies that would benefit from a presentation on PIM since their members could profit by consideration of PIM as a potential growth market, particularly those suffering from the decline in the Australian auto industry.

6. Recommendations

24

The above professional associations are directly associated with the production aspects of the technology. It is equally important that those along the Supply/Value Chain are knowledgeable about PIM and the options it affords such as:

• Design Institute of Australia – industrial designers

• Engineers Australia

• Those representing manufacturers who require component parts such as the Furniture Industry Association of Australia (FIAA)

6.5 Education and Training The knowledge of PIM part design guidelines needs to be made available to engineering design students in TAFE and university courses in order that they then take the knowledge into engineering companies nationwide.

Up-to-date research into powder injection moulding calls on post-graduate level material science, but most other aspects of the technology are within the capability of TAFE.

In fact, many aspects are duplicated by both TAFE and universities due to the recent changes in manufacturing and design processes brought about by the use of CAD, CAM and CAE software in manufacturing companies.

Technicians, tradesmen and engineers collaborate increasingly in the design and manufacture stages of the product lifecycle.

• The TAFE system Training Package MEM05, the Metals and Engineering, has the following units of competency suitable for modification:

VBP263 “Implement Basic Materials Science Principles to Engineering Applications”. Under section 5.1 of the competency ‘Required Skill and Knowledge’ point number 11 should include the word ‘sintering’.

MEM 24.12A A “Apply Metallurgy Principles”. Add another element to this competency; “Interpret and Apply the Principles of Powder Metallurgy”.

VBP250 “Set up Manufacturing Processes for Engineering Applications”. This is a new competency that makes specific mention of powder metallurgy and can be contextualized for Powder Injection Moulding if the equipment is available. It would is not necessary to amend this competency.

• Dual sector educational institutions are well placed to support PIM producers with practical skills as well as scientific expertise.

• There are many relevant skills available in the TAFE sector with existing training packages covering tool making, injection moulding. At the Polymer Centre at Kangan Batman TAFE there is a graduate certificate in plastic tool design in to which PIM technology can be incorporated.

• The office of the Curriculum Maintenance Manager to provide for a presentation on PIM at one of the annual Engineering Senate conventions so that TAFE engineering teachers are aware of PIM and how it compares with other manufacturing processes.

• A similar opportunity to be provided to university engineering design teaching staff to attend a presentation on the set of circumstances when PIM is the most appropriate method of production.

• Once these two groups, TAFE teachers and university lecturers, are aware of the PIM manufacturing process there should be a discussion about cooperation and collaboration in providing the skills needed by a local PIM industry.

6. Recommendations

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• The CIRP network is preparing a Europe wide initiative to maximize collaborative efforts through virtual laboratories similar in concept to a virtual company. Australian universities could be seeking to participate in a PIM virtual lab as soon as business demand for research picks up. There are Australian representatives at CIRP.

6.6 Community It is Rowntree’s opinion that the community be provided with a choice on the basis of quality and value. Australian producers need an unambiguous message from consumers, so that they can allocate resources to projects where there is competitive advantage and the choice is available for Australian designed and produced products.

6.7 Ways in which ISS can be InvolvedKnowledge and Skill Transfer The ISS Institute hosts’ seminars and workshops and one of these could be an engineering design workshop where PIM part design guidelines could be presented and demonstrated.

Several experts in part design, tool design and material design could address the needs of local toolmakers and plastic injection moulding operators looking for new opportunities through an ISS Institute forum. A representative from Austrade could provide insights for small producers new to export.

Business DevelopmentWhere joint ventures or strategic partnerships are appropriate, the ISS Institute could play a role helping to introduce people, particularly with business services such as consulting metallurgists and people with experience in particular countries or industries.

Leveraging the OpportunityRowntree strongly recommends that the Victorian Government continue to provide funds in support of ISS Institute’s Fellowship Program to provide professional development opportunities for TAFE staff whereby the benefits flow into TAFE through:

• Building a highly skilled and knowledgeable teaching staff

• Curriculum development in-line with overseas perspectives

• Students have access to learning environments which are industry-related

• Industry gains by having students graduate with skills and knowledge in current technologies

6.8 Knowledge Transfer – Applying the OutcomesThe Report will be sent to the relevant “Industry Skills Council (ISC)” and Victorian Industry Training Board (ITB) and other stakeholders. Rowntree will be available to meet with ISC and ITB to discuss curriculum outcomes related to training package development. International exchange opportunities are open to be further developed in both business and education.

Rowntree has a website dedicated to supplying basic information on powder injection moulding. The URL is www.smallmouldedparts.com. Here information on PIM and related fields is available including multimedia animations of injection moulding, materials information and reviews of the current research literature.

6. Recommendations

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The fellow is actively seeking speaking engagements especially with industry associations and educators networks in order to promote the development of a PIM industry in Australia.

An article by the fellow on PIM was published in a recent issue of Beyond NTTF, the magazine of the NTTF Alumni Association representing 500 Australian graduates of an Indian toolmaking college now living and working in Australia.

An article is planned in a forthcoming issue of Tooling Australia.

6.9 Further Skill Gaps The field of rapid prototyping has been developing for some years now and attention is beginning to move to rapid manufacturing where the output of the rapid prototyping machines is fast enough and durable enough for actual service. Rapid manufacturing has a long way to go yet and an intermediate step is rapid tooling. Early rapid tooling was problematic during the 1990’s but recent developments may warrant further investigation. Rapid tooling bypasses limitations imposed by the traditional methods of producing tooling.

Whether the technology of rapid tooling is sufficiently mature yet or will be in a few years, Australian toolmakers should be prepared to exploit the removal of limitations imposed by traditional methods of tool making. For example, hollow shapes can be produced which were impossible by milling. Also cooling channels can perfectly follow the contour of the part within the tool and provide optimal cooling conditions.

International exchange opportunities are open for further development by both business and education training institutions.

6. Recommendations

27References

1 Randall M. German and Animesh Bose, Injection Molding of Metals and Ceramics, Metal Powder Industries Federation, Princeton, NJ, 1997.

2 Randall M. German, Powder Injection Molding Design and Applications, Innovative Material Solutions, Inc. State College, PA, 2003.

3 http://cordis.europa.eu/paxis/src/veneto_region.htm

4 http://www.cirp.net/

5 Donald F. Heaney, Qualification Method for Powder Injection Molded Components, P/M Science and Technology Briefs, vol 6, no. 3, 2004, pp. 21-27.

6 Ross Brindle, Powder Metallurgy and Particulate Materials Vision and Technology Roadmap, Metal Powder Industries Federation, 2001, retrieved 23rd January 2007 (http://www.mpif.org/roadmap.pdf)

A list of research papers can be found at http://smallmoldedparts.com/research

28Attachments

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QUALIFICATION METHOD FORPOWDER INJECTION MOLDED COMPONENTS

Donald F. Heaney, Associate DirectorThe Center for Innovative Sintered Products

The Pennsylvania State University118 Research Building West

University Park, PA 16802

ABSTRACTThe PIM process produces net-shape or near net-

shape parts at a reduced manufacturing cost; how-ever, significant process and product qualification isrequired to ensure that the final product is accept-able. The level of qualification depends upon the enduse of the product. It could be as simple as making aprototype part or as complicated as characterizingand controlling the entire process. As a rule, medicaland aerospace products require the greatest amountof qualification and less critical products such as toolsand consumer products require the least. In this pa-per, a guideline is presented to qualify a PIM processthat meets a final specification at a minimum cost. Arationale for choosing only the most critical processcontrol methods is presented.

INTRODUCTIONPowder injection molding (PIM) is a process that al-

lows the formation of net shape or near-net shape partsat a reduced manufacturing cost as compared to machin-ing and at a higher precision level than other forming tech-nologies such as casting. Example PIM parts are shownin Figure 1. However, the process is fairly complicated,requiring knowledge from various disciplines to ensurethat quality product is manufactured. Knowledge of pow-der handling, powder sintering, injection molding, powder/polymer rheology, polymer degradation, metallurgy, etc.must be understood and used to ensure a stable processand a quality product.

Based on the complexity of the PIM process, an engi-neer can get lost in all the possible variables that could beimplemented to attain a controlled process, and most impor-tantly, a quality product. Often, a high level of process con-trol is required and other times it is not. In this paper, aprogram is presented for a design engineer to easily deter-mine the proper material for an application, to qualify a com-ponent vendor, and finally to have a design engineer under-stand the PIM process well enough to make intelligent deci-sions with regards to the use of PIM in their applications.

Figure 1. Example of PIM parts after sintering.

THE POWDER INJECTIONMOLDING PROCESS

To use and to validate the PIM process, a design engi-neer must have a basic understanding of the process. Theprocess must be divided into its sub process categories.The number of process steps can be as many as 9. Thenumber of steps depends upon the particular technologyand the amount of processing that a manufacturer per-forms. For example, whether the manufacturer purchasesfeedstock or manufactures the feedstock in-house. ThePIM process is schematically represented in Figure 2.The process steps are as follows:

I. Raw Material Selecting and MonitoringII. Material BlendingIII. Feedstock CompoundingIV. Injection MoldingV. Solvent or Catalytic DebindingVI. Thermal DebindingVII. SinteringVIII.Secondary Operations (HIP, machining, heat

treating, grinding, etc.)IX. Inspection and Packaging

*contact author:e-mail: [email protected]

P/M Science & Technology Briefs, Vol. 6, No.3, 2004, pp.21-27.

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Process Step Process Input Process OutputBlending Powder & Binder Powder/Binder MixtureCompounding Powder/Binder Mixture FeedstockMolding Feedstock Green PartDebinding Green Part Brown PartSintering Brown Part Finished Part*

Table I. Process Input and Output Products for Comprehension and Process Control

* may require secondary operation

Figure 2. A schematic representation of the metal injectionmolding process

Each process step produces a product that feeds the nextstep. Thus, controls can be performed on the individualprocesses and also on the product of each step to ensurethat the entire process is in control. Table I lists a PIMprocess sequence and the inputs and output of each subprocess.

PRODUCT QUALIFICATION METHODThe first question that must be asked is whether PIM

can be used for an application. This is a two-sided ques-tion. First, is it technically feasible, and second, is it eco-nomically feasible. With this in mind, one must determinethe economics of using the PIM process versus the cur-rent fabrication technique or conventional method for anapplication. If the economic exercise is successful, thenext step is to determine the required application proper-

Figure 3. Logic diagram to go from concept to productionfor PIM

ties and critical dimensions on the component. Prototypemold fabrication is then performed and candidate materi-als are selected. This is followed by near net shape partfabrication and application testing. Figure 3 shows a logicdiagram that can be followed to get a PIM part fabri-cated and qualified.

The first step in qualifying PIM for an application is todo the economic analysis. If the economics look undesir-able, one must return to a conventional manufacturingtechnique or make design modifications in material typeor part size to make the project economical. Often thesize of the part will dictate whether PIM can be used, notonly from a technical point of view for removal of thebinder, but also because of the powder cost. Typically,parts greater than 300 grams cannot be fabricated eco-nomically using contemporary PIM technology. After asuccessful economic analysis, the next step is to look atthe technical aspects of the component – specifically theapplication data such as property requirements and criti-cal dimensions. After these have been defined, the propermaterial or group of materials is selected for evaluation.These materials are then injection molded and evaluatedfor properties, such as tensile strength and/or corrosionresistance. Property evaluation can be skipped if a ven-dor has defined these data in previous work. Satisfactoryresults for properties justify the fabrication of a prototypemold. “Prototype” is emphasized since these parts are


Qualification Method for Powder Injection Molded Components

35

23

produced using low cost tooling. More detail on proto-type molds is presented in the following section on “PIMPrototype Methodology”. The prototype parts might re-quire secondary operations that would not be requiredwhile using production tooling. Application testing is thefinal test to validate that PIM can be utilized for an appli-cation. If application testing is unsuccessful, the develop-ment cycle starts again with design modifications andeconomic analysis, provided management continues sup-port.

The above methodology is a philosophy. Variations tothis technique may exist for different applications, differ-ent amounts of available capital, and also considering timeto market for a product. For example, one may choose togo directly to production tooling fabrication and do thedevelopment on the production tool.

PIM PROTOTYPE METHODOLOGYFollowing the economic analysis, the first step for any

potential PIM application is the evaluation of mechanicalproperties of potential materials and the production of pro-totype parts. The production of test samples (tensile, fa-tigue, wear discs) or actual prototypes is done to test anew material for a particular application with the mini-

Table II. Materials Selection GuideMaterialFamily

Applications Specific Alloys Specific Feature

17-4PH Strength, heat treatable,processability

316L Corrosion resistance, elongation,processability

410L, 420L, 440C Hardness, wear resistance, heattreatable

Stainless Steel Medical, Electronic,Tools, Sporting Goods,Aerospace, ConsumerProducts

430L Magnetic response2200 Magnetic2700 High nickel46058620 Case hardenable4140

Low AlloySteels(heat treatable)

Tools, Bearings, Races,Consumer Goods

52100M2 Low costM4 ProcessabilityT15 High speed, processabilityM42 High speed, processability

Tool Steels(heat treatable)

Wood and MetalCutting Tools

H13Ti Light weightTitanium Medical, Aerospace,

Consumer Products Ti-6Al-4V Light weight, high strengthCu High thermal and electrical

conductivityCopper Electronic, Thermal

ManagementW-Cu, Mo-Cu High thermal conductivity, low

thermal expansionFe-3%Si1

Fe-50%Ni1Magnetic Electronic, solenoids,

armatures, relaysFe-50%Co1

WC-5Co Higher hardnessHardmetals Cutting and WearApplications WC-10Co Higher toughness

Ta ElectronicRefractoryMetals

High Temperature,High Density,Electronic

W-Ni-Cu, W-Ni-Fe High density

Alumina Low costZirconia High wear resistanceSilicon Carbide High wear resistance

Ceramics Wear applications,Nozzles, Ferules

Silicon Nitride High performance

mum of cost. Property evaluation can be as simple aslocating property values in the MPIF standards manual, aPIM part supplier’s specifications, or from other litera-ture that pertains to a specific material. Special and newmaterials may need to be evaluated independently, sincePIM is a relatively new technology and not all data areavailable. Also, mechanical properties can be PIM partsupplier dependent, since all suppliers use different pro-cessing methods and raw materials. For example, vacuumsintering of stainless steels may reduce its corrosion re-sistance or the feedstock binder may leave a carbon resi-due that could compromise properties or corrosion resis-tance of the sintered metal.

Material Selection:Selection of the proper material for a particular appli-

cation often decides the success of a PIM project. TableII lists some available metal alloy and ceramic systemsand potential applications. The specific features are ascompared within the family of material. From this, a de-sign engineer can obtain an approximate idea of the propermaterial for an application. Sometimes, multiple materi-als are evaluated for an application and a decision is madebased on performance, cost, and input from a PIM partsupplier or expert.


D. F. Heaney

36

24

There are other materials available and these can becustom made by a talented PIM parts supplier. As a gen-eral rule, if a material is available in a fine powder form, itcan be powder injection molded. Some exceptions arematerials that have high strength at high temperatures,since these materials are difficult to sinter. A good ven-dor or PIM design engineer should be able to work withyou to select the proper material once you have deter-mined the family of materials that is appropriate for yourapplication.

Prototype Production:A PIM prototype is a PIM part that has been fabri-

cated using the PIM process; however, the tooling that isused is much less in cost than production tooling. A pro-totype tool will cost less than one quarter the cost of aproduction tool, since expensive mold components suchas slides and cams are not used. Difficult features aremachined in as secondary operations, since fewer than1,000 prototype parts are typically produced. The toolingis also made with easy to machine metals such as P20and unhardened H13. Aluminum can also be used, how-ever, this metal is easily dinged and mauled during proto-type development. It is often valuable to have your moldshop work with materials that they are accustomed tomachining. Examples of prototype tooling are shown inFigure 4.

PROCESS CONTROLOnce a PIM prototype part has passed initial qualifi-

cations for use, the next step is to ensure that a process issufficiently in control for a particular application. Mini-mum process control is required if the specifications are

Figure 4. Example of Prototype tooling. No details requir-ing slides or cams are on the part

broad and a significant amount of process control is re-quired if the specifications are narrow. This section breaksdown the PIM process to allow one to determine whatare the needs for a specific PIM process to achieve therequired specifications at the minimum of cost.

To analyze the PIM process for process control, theprocess must be divided into its sub process categories.Each of these sub processes can be controlled to ensurea more repeatable process; however, the more you moni-tor, the more costly is the overall process. Therefore, anengineer must balance between cost and control to en-sure that the PIM process is profitable for a particularapplication. For example, if a company is doing aero-space or medical parts, where the cost of a catastrophicfailure is high, there must be a high level of process docu-mentation and control. A company that manufacturesproducts that have less financial exposure for catastrophicfailure would require less. The general concept is to pro-duce the best possible product with the least amount ofprocess monitoring.

Table III lists each of the process steps for powderinjection molding, and also the parameters that could becontrolled for that process step. Although there are manypotential parameters to control in the PIM process, not allneed to be controlled. Application and process type de-fine the required control. Table IV lists a comparison ofprocess control auditing for two levels of control. Oneprocess control would be considered minimum in both costand effort whereas the other provides precise control forprecision and high performance components.

CONTROL PARAMETER UNDERSTANDINGThe following section is devoted to describing the dif-

ferent process controls and the reason for their use. Thesecan also be used in the process setup and qualificationstage to ensure a stable process and reviewed periodi-cally or when a problem arises.

(1) Powder Characteristics

Chemistry: Chemistry monitoring is most critical formaterials that are sensitive to carbon level and oxygenlevel, however, other elements such as chromium for stain-less steels may be important to monitor. Carbon level isrequired for materials where it is important for propertiesand heat treatment. The most common being tool steels,low alloy steels, and martensitic stainless steel. In thesematerials, it affects dimensional stability, sintered density,and mechanical properties. Also, materials sensitive tocarbon embrittlement, such as titanium, should have thecarbon monitored. Oxygen monitoring is important formaterials such as titanium since it effects the elongation.Also, oxygen in combination with silicon in stainless steels



37

25

Process Step Process Attribute Measurable Attribute Monitor MethodChemistry Specification sheets

Chemistry analyzer

Powder Size Specification sheetsPSD analysis

Powder Size Distribution PSD analysisDensity PycnometryTap Density Tap Density

Powder

Moisture level (ceramic) HydrometerMoisture Level Hydrometer

Raw Materials

BinderViscosity Capillary RheometryDensity (powder/binder ratio) PycnometerViscosity Stability Capillary Rheometry

Compounding Feedstock

Viscosity vs. Shear Rate Capillary RheometrySwitch-over Pressure Switch-over Pressure Stability MachineScrew Return Torque Screw Return Torque Stability MachinePart Part Mass Scale

Injection Molding

Defects Blisters, Voids, Cracks,Powder/Binder Separation,Knit Lines

Visual, X-ray

Part Mass Loss ScaleSolvent DebindingDefects Cracks, Blisters VisualPart Mass Loss ScalePart Shrinkage Linear Measurement

Thermal Debinding

Defects Cracks, Blisters VisualMaximum Temperature Max Temp Stability ThermocoupleTemp. Uniformity Temp Uniformity Stability ThermocoupleDefects Voids, Cracks Visual, X-rayPart Shrinkage, Final Dimensions Linear MeasurementPart Surface Finish ProfilometerPart Corrosion Resistance Salt spray,

poteniodynamic scans

Sintering

Part Properties Application testingPart Dimensions Linear MeasurementInspectionGauging Dimensions Linear Measurement

Table III. Potential Parameters to Control for the PIM Process

may effect the elongation by the formation of silica par-ticles.

Powder Size and Size Distribution: Powder sizeand size distribution affects mixture viscosity and injec-tion molding. As particle size increases, mixture viscositydecreases. This affects the molding process consistency.Also, sintered density and mechanical properties are af-fected by the powder size. As particle size decreases,the sintering response increases. Therefore, variability inparticle size affects the part dimensions, part density, andmechanical properties.

(2) Feedstock Behavior

Pycnometer Density: Pycnometer density is a directmeasure of the ratio between the powder and the binder.

Improper pycnometer density effects sintered size, mix-ing viscosity, and molding.

Feedstock Viscosity: Improper feedstock viscositywill result in variability during molding and part quality. Italso can be an indication of improper raw materials, de-graded raw materials, degraded feedstock, and poorlymixed feedstock.

(3) Injection Molding

Part Mass: A variation in part mass will result in avariation in dimensions in a sintered part. The part massvariability may be the result of the feedstock preparationstep or of barrel temperature variability. Variability in theswitchover position or hold pressure can cause mass vari-ability and final part dimensional variability.


D. F. Heaney

38

26

(4) Debinding

Weight loss: Understanding the amount of binder inyour part and the rate at which it is removed is critical fordefect free parts. Also, if the binder is not removed cor-rectly, there is a chance that “ash” will form in the part,put excess carbon in the part, and affect the final me-chanical properties of the parts.

(5) Sintering

Select part dimensions: Dimensional variabilityshows the most effect after sintering. As the tempera-ture in the furnace varies, so do the dimensions. There-fore, knowledge of the dimensions and how they vary areimportant to understand the sintering process and to main-tain a controlled process. The variability of all the previ-ous process steps will be exasperated in the sintering stepand show up as part dimension variability.

Part mass: After sintering, the mass of a com-ponent can change if there is an alloying element thatvaporizes in the furnace. For example, the loss of chro-mium in stainless steel during vacuum sintering is welldocumented.

Attribute Minimum Control Precision ControlFeedstock • As-molded part mass auditing • As-molded part mass

auditing• Pycnometer density

auditing• Viscosity stability auditing

Injection Molding • Part mass auditing• Position switch-over and

monitor switchover pressure

Part pycnometerdensity

Part dimension. Cavity pressure

switch-over and monitorswitchover position, closed-loop control on hold pressure

Solvent Debinding . Weight loss studies Weight loss studies. Weight loss auditing

Thermal Debinding I. Weight loss studiesII. Weight loss auditing

Sintering • Select part dimension auditing• Part mass auditing

• Select part dimensions• Part mass• Chemistry analysis• X-ray• Crack detection• Microstructure• Mechanical Testing

Table IV. Process Auditing Comparison for Minimum and Precision Process Control

Chemistry analysis: Material evaporation orcontamination from the furnace or process gas can bedetected to high accuracies using chemistry analysis.

X-ray: Voids and cracks are easy to detect usingX-ray equipment. This could be used for the setup ofcritical parts for medical or aerospace applications.

Crack detection: Many methods exist for thedetection of cracks. These can range from acoustics tovisual detection.

Microstructure: The evaluation of microstruc-ture can be extremely valuable. The detection ofoversintered or undersintered microstructure is simpleusing this method. Also, many other characteristics ofthe part can be detected from the microstructure. Theseinclude carbide formation, phase ratios, etc.

Mechanical testing: Often, the components can beput through function testing for strength or evaluated forhardness on the actual part. Another method to monitor thesintering process is to have test specimens sintered with theparts and evaluate the test samples for strength, elongation, orsome other test.



39

27

CONCLUSIONA method to qualify powder injection molding for an

application was presented. This was done for both prod-uct and process. A thorough evaluation of process con-trols and monitoring that can be done on a PIM processwas laid out. Also, a rational for the selection of the bestprocess control for a particular application has been pre-sented. In general, one should monitor only the most criticalparameters that are dependent upon the application andits specifications.

ACKNOWLEDGEMENTSThe author is grateful to the Center for Innovative

Sintering Products for the opportunity to practice powderinjection molding and to Randall M. German for review-ing and offering his insight to this manuscript.

References1. MPIF Standard 35, “Materials Standards for Metal Injection Molded

Parts”, 2000 edition.2. Powder Metal Technologies and Applications, ASM Handbook,

Vol. 7, ASM International, 1998.3. R. M. German, Powder Injection Molding Design and Applica-

tions, IMS, Inc., 2003.4. D. Heaney, R. Zauner, C. Binet, K. Cowan, and J. Piemme Variabil-

ity of Powder Characteristics and their Effect on DimensionalVariability of Powder Injection Molded Components, Journalof Powder Metallurgy, v. 47, n. 2, 2004, pp 145-150.

5. R. Zauner, C. Binet, D. Heaney, J. Piemme: Variability of FeedstockViscosity and its Effect on Dimensional Variability of GreenPowder Injection Molded Components, Journal of Powder Met-allurgy, v. 47, n. 2, 2004, pp. 151-156 .

6. EPMA Metal Injection Molding Standards Handbook,2000.


D. F. Heaney

40

VISION AND TECHNOLOGY ROADMAPPOWDER METALLURGY AND PARTICULATE MATERIALS

SEPTEMBER 2001

SPONSORED BY

U.S. DEPARTMENT OF ENERGY

OFFICE OF INDUSTRIAL TECHNOLOGIES

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PM2 Industry Vision and Technology Roadmap

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DEFINITIONS

P/MThis is the abbreviation that refers to the powdermetallurgy process used to create semi- and fullydense components from metal powders.

PMThis term refers to “Powder Metallurgy andParticulate Materials”, denoting the use of the P/Mprocess with both metal and non-metal particulatematerials. PM is used to refer to the industry whichuses these materials to create components.

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Overview of PM Industry Vision and Technology Roadmap2

Increase non-automotive marketsby 25% per year through 2020

STRENGTHENING AND FINISHING

PROCESSING CHALLENGES

FORMING

MANUFACTURING SCIENCE

ADVANCED COMPACTION

3-D FORMING

RAPID MANUFACTURING

EQUIPMENT AND TOOLING

Enhance productivity by 5% eachyear through 2010 and 8% by 2020

Increase automotive marketby 12% per year through 2020

PRODUCTIVITYAUTOMOTIVE

NON-AUTOMOTIVE

Achieve six-sigma quality forall components by 2005; achieveAGMA 9 by 2005 and AGMA 10by 2020 at six sigma

Increase university and technicalschool graduates entering thePM industry by 500% by 2010

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QUALITYHUMAN RESOURCES

Reduce overall energy consumptionby 50% by 2010 and 80% by 2020

ENERGY & ENVIRONMENT

MODELING

CROSS-CUTTING CHALLENGES

DESIGN TOOLS

SENSORS AND CONTROLS

TESTING AND DEMONSTRATION

STANDARDS

R&D STRUCTURE

Develop new energy efficientsintering techniques

Minimize process interruptionsto move to more continuousproduction

Methods to achieve fulldensity with tight dimensionaltolerance cost effectively

Rapidly form complex3-D components (selectivelaser sintering, rapid prototyping)

Systems for more rapidmanufacture of products

Increase automation, uptime,and speed

Non-traditional processingtechniques

User-friendly math-basedprocess models

Use new or existing sensortechnology in innovative ways

Develop a web-baseddesign advisor

Establish agile PM test-bedfacility to gather data

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Develop standards closerto actual application

Form collaborativepartnerships with otherindustries and government

Explore fine particle andnanocrystalline powders

Improve understanding ofpowder microstructure-performance relationships

Study method of cosinteringcomposites with differentmaterials

Explore new materials to betterunderstand properties, processes,and potential applications (finestructured, amorphous, etc.)

POWDER PROCESSING

MATERIALS CHALLENGES

NEW MATERIALS

MATERIAL SCIENCE

COMPOSITE MATERIALS

Insufficient knowledge ofporosity-property relationships

Shortage of thermophysicaldata for new materials

Inability to compact to 100%density with dimensionalaccuracy at low cost

Lack of 3D forming processesfor large components

Lack of process models andin situ sensors for materialsand process controls

Shortage of non-intrusivesensor materials

MATERIALS PROCESSING ENABLING

MARKET GOALS

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Annual Sales $2.0 billionEmployees 6,000No. of Companies 400

Annual Sales $300 millionEmployees 3,700No. of Companies 100

Annual Sales $5 billionEmployees 30,300No. of Companies 700

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THE POWDER METALLURGY PROCESS

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MOST CRITICAL TRENDS AND DRIVERS

Decreased auto industry dependence oninternal combustion engine

Growing customer demand for high-performance materials

Shift in net-shaping to less reliance on machiningand sintered cutting inserts

Increasing need for more precise net-shapedmanufactured products

Move to agile manufacturing while reducingdowntime and achieving six-sigma quality

Increasing supply chain integration throughtotal process modeling and e-business

Limited supply of skilled workers andlimited resource base to attract new workers

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TRANSPORTATION: TECHNICAL AND PERFORMANCE BREAKTHROUGHS

MEDICAL/BIOTECHNOLOGY: MIMICKING NATURAL GROWTH PROCESSES

ELECTRICAL/MOTORS: MAGNETIC MATERIALS AND MICROMOTORS

CUTTING TOOLS: COST REDUCTIONS VIA NANOPARTICLES

Historically, the transportation market has been the most technically demanding marketserved by the PM industry, whether it is the automotive or aircraft segment. The valueand opportunity for PM is derived from the need for performance and reliability. Theauto segment offers volume to provide the cost support necessary to achieve technicalbreakthroughs. The aircraft segment offers the high value of each component (whereinmany cases, cost is less a concern than reliability and performance) to justify thedevelopment of new technologies to realize performance breakthroughs. Material systemselection and improved consolidation techniques have enabled those breakthroughs. Theindustry expects that this market sector will continue to offer similar opportunities.

The continued development of insulated powders for hard and soft magneticapplications will fundamentally change the opportunities for the design of motors.Designers will no longer be constrained to use stacks of laminations to build motors.The flexible shapes that can be pressed or molded into stators and armatures using PMconsolidation techniques and powders without a loss in electrical performancecharacteristics will revolutionize this sector. In addition, advanced consolidationcapabilities will enable production of “micro” motors using new materials. With theadvent of hybrid propulsion systems for transportation, the design and weightadvantages of PM will presage a major market opportunity for the technology.

PM technology has enabled the significant advances achieved to date in cutting andforming tools used in all metal removal processes. The use of new “harder” andtougher materials will continue to permit advances in machining and forming. Theseadvances will be enabled by using nanoparticles of various materials and existing metalsand ceramics to achieve breakthrough performance. The value of this technologycannot be underestimated in its importance to continued metal processing productivityand cost reductions.

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The ability to cost effectively provide complex net-shape design options withoutextensive machining requirements will continue to attract designers in this sector to PM .In addition to the shape of the components, the unique flexibility inherent in PM toprovide complex, definable material structure and particle morphology will be viewed asa unique advantage of the technology. PM ’s particulate, “building block”, consolidationcapabilities that do not require the damaging effects of melting and solidification willoffer this segment the opportunity to develop fabrication techniques that will mostclosely mimic natural processes of growth and formation of structures. The materialselection options for strength and biocompatibility will offer unparalleled futureopportunity for technical success.

SELECTED MARKET SECTOR BRIEFS

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PM INDUSTRY STRATEGIC GOALS

Markets and Customers: Achieve 12% annualmarket growth for automotive markets and 25% fornon-automotive markets through 2020.

Productivity: Enhance productivity by 5% everyyear through 2010, and 8% through 2020.

Time Compression: Reduce total time to marketfrom two years to six months by 2010, and onemonth by 2020.

Quality: Achieve six-sigma quality for allcomponents by 2005; achieve AGMA 9 by 2005and AGMA 10 by 2020 (at six sigma).

Human Resources: Increase university andtechnical school graduates entering PM industry

2

by 500% by 2020.

Energy and Environment: Reduce overall energyconsumption by 50% by 2010 and 80% by 2020.

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Overview of PM Industry Vision and Technology Roadmap2

Increase non-automotive marketsby 25% per year through 2020

STRENGTHENING AND FINISHING

PROCESSING CHALLENGES

FORMING


ADVANCED COMPACTION

3-D FORMING

RAPID MANUFACTURING


Enhance productivity by 5% eachyear through 2010 and 8% by 2020

Increase automotive marketby 12% per year through 2020

PRODUCTIVITYAUTOMOTIVE

NON-AUTOMOTIVE

Achieve six-sigma quality forall components by 2005; achieveAGMA 9 by 2005 and AGMA 10by 2020 at six sigma

Increase university and technicalschool graduates entering thePM industry by 500% by 2010

2

QUALITYHUMAN RESOURCES

Reduce overall energy consumptionby 50% by 2010 and 80% by 2020

ENERGY & ENVIRONMENT

MODELING

CROSS-CUTTING CHALLENGES

DESIGN TOOLS

SENSORS AND CONTROLS


STANDARDS

R&D STRUCTURE

Develop new energy efficientsintering techniques

Minimize process interruptionsto move to more continuousproduction

Methods to achieve fulldensity with tight dimensionaltolerance cost effectively

Rapidly form complex3-D components (selectivelaser sintering, rapid prototyping)

Systems for more rapidmanufacture of products

Increase automation, uptime,and speed

Non-traditional processingtechniques

User-friendly math-basedprocess models

Use new or existing sensortechnology in innovative ways

Develop a web-baseddesign advisor

Establish agile PM test-bedfacility to gather data

2

Develop standards closerto actual application

Form collaborativepartnerships with otherindustries and government

Explore fine particle andnanocrystalline powders

Improve understanding ofpowder microstructure-performance relationships

Study method of cosinteringcomposites with differentmaterials

Explore new materials to betterunderstand properties, processes,and potential applications (finestructured, amorphous, etc.)

POWDER PROCESSING

MATERIALS CHALLENGES

NEW MATERIALS

MATERIAL SCIENCE

COMPOSITE MATERIALS

Insufficient knowledge ofporosity-property relationships

Shortage of thermophysicaldata for new materials

Inability to compact to 100%density with dimensionalaccuracy at low cost

Lack of 3D forming processesfor large components

Lack of process models andin situ sensors for materialsand process controls

Shortage of non-intrusivesensor materials

MATERIALS PROCESSING ENABLING

MARKET GOALS

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TIME COMPRESSIONGOAL:

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Insufficient knowledge of porosity-property relationships

MATERIAL SCIENCE

- Uncertainty with assumptions made in materials characterization

Incomplete knowledge of relationships between material phases/constituents,properties, and performance

Inconsistent understanding of material science (in its application to particulatematerials) throughout the industry

Shortage of thermophysical data, specifically for new materialsResistance to the qualification of new materials and processes due to lack ofstandards and material property data

Inability to manufacture large volumes of composite materials at low costLack of methods to sinter functional laminates

INNOVATIVE MATERIALS

COMPOSITE MATERIALS

Exhibit 5-1. Enhanced Material Properties and Performance – Critical Barriers

Difficulties controlling critical powder characteristics (e.g., surfacecontamination, size distribution, etc.) during powder production

- Inconsistency and limited repeatability of powder production

Inability to process, handle, and monitor fine powders

Lack of standards for blending powders

POWDER PROCESSING

- Problems include flowability, mixing, and health and environmental concerns

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2001 2004 2010 2020

Mid-Term Long-Term

ENHANCED MATERIAL

PROPERTIES AND

PERFORMANCE

MATERIAL

SCIENCE

NEW

MATERIALS

Materials for alternativefuel vehicles(fuel cells, hybrid, etc.)

New materials development usingexisting technology

Novel alloy production

Low-creep, high-temperature materials

Property data for light-weight materials(MMCs)

Understanding of process-microstructure-performancerelationships

Research material properties between90% and full density

Thermophysical data development

Understand new material properties,processes, and applications (100%engineered materials, functionallygradient materials fine structured,amorphous, metallic glasses, etc.)

Materials single-pressed to full density

Material with elastic modulus 50% greaterthan steel

Self-sintering powders

Fundamental porosity-property studies

Biomedical materials research

Research organic powder interaction(metal-powder interface)

Ability to predict properties frommicrostructure

Study compatibility of functionally gradientmaterials

Innovative magneticmaterials

Customize productsbased on applicationof material scienceprinciples

COMPOSITE

MATERIALS

Study the feasibility andperformance/cost benefits forcomposites

Methods to add value to structures inthe P/M phase

producible from powders

Co-sintering composites withdifferent materials

Low-cost composite materialsapplications

Custom compositepowders of differentmaterials (biological,plastics, etc.)

POWDER

PROCESSING

Novel approaches to conventionalpowder manufacture

Assess powder measurementtechniques using inter-laboratory testing

Fine, clean powder use to facilitatefull density

Powder handling technology as itrelates to powder uniformity

Fine particle technology andnanocrystalline powders

- compaction- material properties- sintering

Improved atomization technology(particle size distribution)

Blending and dispersal methods forpowder mixtures

Research particle reactions, intense atomizationprocesses for droplet control (in situcomposites with tolerance control)

Economic manufactureof sub-micron particlesat production scale

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Exhibit 6-1. Improved Processing and Manufacturing – Critical Barriers

Limited size range in component forming and processing


Property variation within parts- Lack of methods to measure critical variables such as density inhibits greaterpart uniformity

Inability to predict the long-term behavior and consistency of a part produced froma given batch

Difficulties creating controlled porosity

Tendency to develop point solutions rather than underpinning technologies formultiple applications

- e.g., biomedical, lightweight, telecommunications, and other applications.

Inadequate alloys and finishing processes to provide superior corrosion resistanceUnknown correlation between surface and near-surface properties as a function offinishing processes

STRENGTHENING & FINISHING

Lack of predictability in current sintering methods

ADVANCED COMPACTION

Inability to compact to 100% density with tight dimensional control and accuracyat low cost

- Presence of residual pores in PM parts2

Excessive use of and ineffective lubricants- Insufficient friction reduction adversely effects compaction energy, energy gradients,and size

High frequency of green density variations- Component complexity is accelerating faster than equipment control methods

3-D FORMING

Lack of efficient, accurate, and cost-effective 3-D forming process for largecomponents

RAPID MANUFACTURING

Inability to utilize rapid manufacturing in productionSintering process can be time consumingInability to rapid prototype to production-level tolerances


Inability to process increasingly complex shapes while adhering to morestrict design tolerancesIncreasing capital intensity in relation to sales

WASTE REDUCTION

Lack of scrap and waste recycling technologies (e.g., planned design andseparation technology)Meeting current and future environmental regulations

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2001 2004 2010 2020

Mid-Term Long-Term

More easily removable,lower-friction lubricants

Wear-resistant die materialsor coatings

Material and process systems toeliminate porosity cost effectively withtight tolerances (powder design,reduced lubricants, higher-densitycompaction, and enhanced sintering)

Improved MIM part debinding

Low-cost compaction devices

Reduce process variations toimprove tolerances

Materials and processes to makelarge and small parts economically

Improved welding and joining techniques

Methods to tailor powder fill- increase powder fluidity/uniformity- decrease lubricant use

Non-traditionalprocessing techniques

MANUFACTURING

SCIENCE

Accurate, rapid measurement oflocalized green properties

Novel applications of currentprocessing techniques

Higher efficiency furnace designs(productivity and energy)

Minimize process interruptions to moveto more continuous production

Understanding of basic process phenomena

Understanding of density variation impactson tolerances

Manufacturing process flexibility

Form and sinterin one process

ADVANCED

COMPACTION

3-DFORMING

Research factors critical to3-D forming

- filling, pressing, and tooling- low-friction materials, improvedlubricants

Rapid formation of complex 3-Dcomponents with high density andtight dimensional control

- as fast as current 2-D technology

Binder research- high metal-binder ratio

- cold-form spherical powders- complete binder removal

New techniques forlarge 3-D components

- plastic molding- sintering- infiltration

IMPROVED PROCESSING

& MANUFACTURING

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2001 2004 2010 2020

Mid-Term Long-Term

STRENGTHENING

AND

FINISHINGSintering aids to improve efficiency- low-cost production of coatings

for powders to aid sintering

Improved green compactingand sintering

New sintering techniques with rapidenergy transfer (e.g., microwave)

Improved heat treatment (induction,laser, etc.)

Engineered surface propertiesthrough heat treatment

Machining cost reduction

Processes andmaterials thateliminate sinteringand de-lube

RAPID

MANUFACTURING

Systems for more rapidproduct manufacturing

Rapid tooling capabilities

Rapid productdevelopment cycles(from concept tofinishedcomponentin less thanone week)

EQUIPMENT

AND TOOLING

Improve equipment speed andcapacity to improve capacity utilization

Low-cost, low-volume, quick-changetooling

Diagnostic methods that ensureequipment is yielding consistent product

Advanced equipment and tooling- increased uptime- completely automated- minimal maintenance

WASTE

REDUCTION

Improved process scrap recyclingand utilization

Process waste reduction technology

Lower gas and atmosphere consumption

Robust multi-gas analyzers for dirtyenvironments

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Exhibit 7-1. Enabling Technologies and Infrastructure – Critical Barriers

Inadequate material and process modeling capabilities (e.g., sintering)pressing and

MODELING

Lack of in situ sensors for closed-loop controls and quality assurance- Inability to measure internal cracks in green parts online

Limited process and product control methods

Lack of adequate diagnostic methods to evaluate powder fill and green parts

- Lack of sensors to optimize gas supply systems and gas use during sintering

- Inefficient temperature control for both process heat removal and addition

SENSORS, CONTROLS, AND DIAGNOSTICS

Lack of an integrated database to assist designers in achieving desiredperformance characteristics

- Lack of fundamental phase equilibrium and other data to optimize powder andproduct design

DESIGN TOOLS


Insufficient effort to promote PM industry as a manufacturer of unique partswith unique properties

2

- PM often perceived as offering poorer properties regarding strength, fatigue,toughness, wear, etc.

2

- Customers unaware of all PM capabilities2

Lack of accelerated testing and long-term testing data

Insufficient investment in powder material technology and capital equipmentLimited network of knowledge

- Lack of strategic alliances between powder, equipment, component, andcustomer companies

Limited success in attracting qualified technical and professional staff to the industry- Limited resources and incentives

- Inadequate resources available for education

INDUSTRY RESOURCES

Limited R&D funding (basic and specialized PM applications)2

- Prolongs cutting-edge innovation and market expansion

Minimal information sharing throughout different sectors of the PM industry2

- Inhibits coordinated industry-wide R&D initiatives

- Shortage of partnerships among small companies within the PM industry2

Industry’s inability to escape near-term mindset for R&D

R&D STRUCTURE

Absence of global, uniform design standards and dataLack of electronic communication standards (XML) to facilitate supply chainintegration

STANDARDS

SUPPLY CHAIN INTEGRATION

Incomplete interface between powder maker, equipment/tooling suppliers,powder user, and final customer

- Inadequate communication of customer powder/component property needs- Long-lead time for customer acceptance

Lack of concurrent engineering with customer

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ENABLING

TECHNOLOGIES &

INFRASTRUCTURE

Free-formmanufacturingdesign tool anddevice (build partparticle byparticle, no tooling)

DESIGN

TOOLS

Designer education (at school andon-the-job mentoring)

Risk management tool for designers

Internet-based design advisor- material selection- process selection- design rules- performance- error budgets

TESTING

AND

DEMONSTRATION Establish agile PM test-bed facilityfor gathering data

2

- demonstration test bed for integrationof process models, sensors, andNDE diagnostics

Improved availability of pilot-scalefacilities

Demonstration projects usingintegrated design teamsacross companies

Accelerated life-cycletesting methods

Near-Term

2001 2004 2010 2020

Mid-Term Long-Term

MODELING

Widely available user-friendly, math-based process models with realisticconstraints

Modeling of degradation during service life

“Virtual reality” 3-D plant simulation foruse in design, scale-up, and education

Complete predictivemechanism ofcomponentdegradation andcritical failuremechanisms

Modeling of completeforming andstrengtheningprocessesfor a component

Process modeling for pressing,sintering, gas flow in furnaces, andother processes

Supply chain for integration- use with e-business

SENSORS,

CONTROLS,

AND

DIAGNOSTICS

Understanding of critical parametersto monitor and interrelationships forquality

Enhanced control over powderuniformity

Advanced controls for moremore accurate green compactingand sintering

Low-cost diagnostics techniques torapidly evaluate critical performancecharacteristics of powder and greencomponents

Non-intrusive, stable sensor materialsfor process control

Novel use of new or existing sensortechnology to monitor particle size,particle size distribution, flow rates,and furnace conditions

System-based, closed-loop feedbackcontrols (sintering problem feedsback to earlier process)

Robust multi-gas analyzers fordirty environments

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STRUCTURE

Nurturing environment forformulation/implementationof innovative ideas

Multi-disciplinary university consortia

Collaborative partnerships withother industries (e.g., finishingindustry, lubricant manufacturers,ceramics industry, fiber-reinforcedmaterial producers, etc.)

Near-Term

2001 2004 2010 2020

Mid-Term Long-Term

SUPPLY

CHAIN

INTEGRATION Time-to-market scheme moreresponsive to customer demand

Improved communicationamong supply chain, end users, andR&D personnel

Modeling and e-business forsupply chain integration

Design and implementation ofelectronic communication standards (XML)

INDUSTRY

RESOURCES

Increased commitment to R&D

Internet-based education program

Increased technology demonstrationsupport

Assessment of industry-wide long-range resource planning

Widespread knowledge of competingtechnologies

Cost-effective funding sources forR&D and capital formation

Structure for PM R&D venture capital andequity to be funded by industry, forindustry

Education programs (textbooks) for compositematerials, new materials, and new processes

2

Accurateprediction ofneededproperties,tolerances,and humanresources

STANDARDS

Accelerated property standardsdevelopment (including globalstandards)

Standards development that considersapplication

New standards based on most accurateprocess data available

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TOP-PRIORITY RESEARCH NEEDS

� Develop 3-D forming processes and exploit advanced pressing, tooling, low-frictionmaterials, lubrication, and fill technologies

� Develop material and process technologies to achieve 100% density while maintainingdimensional tolerances and cost-effectiveness

� Develop innovative materials, processes, and material combinations to create advancedmaterial capabilities

� Develop integrated process models, sensors, and NDE diagnosticsto reduce process variation, improve tolerances, and improve process

and supply chain efficiencies

that tie industry togetherfrom user to supplier

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Conduct fundamental characterization studies for new materials: determine property-structure-performance relationships

Minimize process interruptions to move to more continuous production

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IMPLEMENTATION

• Resource integration/allocation• Testing facilities• Identify priorities/applications• Cost-benefit evaluation• New process and technologydevelopment

• DOD–Military aircraft and tankapplications; part configuration

• NIH–Medical implants• Navy–On-board fabrication• DOE–Rapid prototyping offill methods

• NDE capabilities at DOE labs• NASA–Construction materials;lightweight materials

• NIST/ATP–Facilitate verticalcollaboration between powdermakers, equipment providers, partmakers, & OEMs

• Technical and financial resources(risk mitigation)

• Organization and funding of pre-competitive models

• Polymer and chemicals industries• Universities• MPIF, CISP, PMRC, and otherindustry groups facilities verticalcollaboration among PMcompanies and with end-users

• CPMT–Facilitate horizontalcollaboration

• End-users willing to implementnewly introduced technologies

2

GOVERNMENT ROLE POTENTIAL PARTNERS

• Tooling design and techniques- modeling- coatings- finite element analysis- time compression- adjustability- soft tooling

• Processing design and techniques- isopressing- solid free-form fabrication- magnetic fabrication

• Binders• Rapid prototyping• Low-friction materials• Lubrication• Fill methods

• Powder design; powder density• “Monster” MIM• In situ non-destructive evaluation(NDE)

• Sintering time reduction• Press automation• Demonstration mechanism• Furnace design• Gas flow modeling

DESCRIPTION

IMPACT ON GOALS

KEY TECHNICAL ELEMENTS

Develop 3-D forming

processes and exploit advanced

pressing, tooling, low-friction

materials, lubrication, and

fill technology

R&D PRIORITY

LOW HIGH

MARKET GROWTH

PRODUCTIVITY

TIME COMPRESSION

QUALITY

HUMAN RESOURCES

ENERGY/ENVIRONMENT

One of the major limitations of traditional press-and-sinter

technology is that there are only two dimensions of design

freedom, with the third reserved for pressing direction. While

some 3-D consolidation technologies exist (e.g., MIM, HIP),

they are not economical for the majority of components

produced today. Developing the capability to design and form

PM components in three dimensions as quickly and

economically as today's 2-D technology is a technical challenge

that will have huge implications for market expansion and

time-to-market. The degree of technical challenge in

developing 3-D forming technology is extremely high;

accordingly, a wide-reaching collaborative partnership

involving many different representatives from various industry

and related institutions is appropriate.

2

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IMPLEMENTATIONGOVERNMENT ROLE POTENTIAL PARTNERS

• New tooling materials and designs• Isostatic pressing• High-temperature sintering• Liquid-phase sintering• Self-organizing (“smart”) powders• Better equipment utilization

• High-performance press designs• Powder lubrication systems• Press cost reduction• Ultra-compressible powders• Powder morphology• Surface treatments

• Particle size distribution• Powder fill and flow• Sensor and modeling• Die-less technologies• Non-traditional pressingtechniques


Develop material and process

technology to achieve 100%

density while maintaining

dimensional tolerances and

cost-effectiveness

R&D PRIORITY

LOW HIGH

MARKET GROWTH

PRODUCTIVITY

TIME COMPRESSION

QUALITY

HUMAN RESOURCES

ENERGY/ENVIRONMENT

• Champion for new formingtechnologies

• Matching funds for projects• Promotion of fully dense capabilityimportance to government

• Provide system-level view toensure technology can beimplemented in real processes

• Provide testing facilities• Technical and financial resources• Cost-benefit evaluation

• NIST (ATP), DOE, NSF, DOD,PTIA, Ben Franklin TechnologyCenter

• Funding of lubricant,morphology, etc. studies

• Provide neutral, industry-wideplatform

• Access and coordination ofnational laboratory expertiseand testing facilities

• Assistance with risk mitigation

• MPIF, CISP, PMRC, and otherindustry groups facilities verticalcollaboration among PMcompanies and with end-users



• Other industries using pressingtechnologies

• Universities• International partners

2

The density and residual porosity of a PM component play a

significant role in its quality and performance. Achieving the

highest density possible is normally the goal, because as

density is pushed higher the metallurgical properties of the

structure approach that of wrought metal, which is considered

fully dense. Not all current PM applications require full

density and accordingly PM components have been successful.

However, as densities are driven upwards, larger percentages

of the overall fabricated metal products market can be

overtaken by the PM industry as the economic advantages of

PM processing techniques are applied to fully dense

components.

2

2

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2

2

DESCRIPTION

IMPACT ON GOALS

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• Material classes- engineered materials- fine powder/nanocrystalline- magnetic- biocompatible- functionally gradient- multi-material systems

• Thermal/mechanical approaches;matching thermal expansioncharacteristics; thermal sprays;thermal compatibility of precursors

• Powder fill technologies• Fine/reactive material handling• Gradient blending design tools• Suitable material combinations

• Functionality confirmation• Feasibility demonstration• Critical performance parameters• Sensor technologies• Spatial controls• Environmental factors• Standards development


Develop new materials,

processes, and material

combinations to create

new material capabilities

R&D PRIORITY

LOW HIGH

MARKET GROWTH

PRODUCTIVITY

TIME COMPRESSION

QUALITY

HUMAN RESOURCES

ENERGY/ENVIRONMENT

Cultivating new material capabilities is essential for the PM industry

to expand and diversify its markets and realize its goals, particularly

those relating to market growth. Specifically, material capabilities in

the following areas are sought:

• fine particle/nano-crystalline powders and associated handling

technology

• totally engineered, or "tailored", materials that put the right

material in the right place

• multi-functional and functionally gradient materials

• magnetic materials for power systems in alternative vehicles

• bio-compatible materials

• composite materials

These developments will not only open up new market segments

that hold promise for attractive profits and growth, but also help

serve existing markets and customers by offering a broader range of

components with advanced performance. Each of the areas of

materials focus is strategic in that it capitalizes on the unique nature

of the P/M process (namely, powder-based part formation).

2

• Identification of market needsand applications

• Provision for resource integrationand systems perspective

• Information sharing• Powder producers– High-quality, specialized alloysupply

• Raw materials development• Economic analyses• Sintering studies• Standards development

• Test/pilot plant provision• DOE–High-wear applicationanalyses (e.g., mining)

• DOE/NIST–Sensors & controls• NIST–Materials characterizationand modeling

• NASA–Multi-functional materials;thermal barriers

• DOE–Materials applications• NIH–Bio-compatibility studies• ATP• New material needs surveys• National laboratory research

• OEMs–Needs identification• Non-traditional OEMs (e.g.,bioengineering firms; universityhospitals)

• Universities/research laboratories• ASTM• Component producers• Sensor developers/manufacturers• Automotive, aerospace,biomedical, andtelecommunications industries

• Equipment suppliers• Venture capitalists

DESCRIPTION

IMPACT ON GOALS

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• National testing facility• Modeling verification• Modeling expertise capability• Net-shape manufacturing

• Sensor needs assessment tounderstand critical parameters

• Software development• NDE diagnostic tools• In situ online sensors

• High-temperature, high-strengthsensor materials

• Database development; datacollection for large-scale processes

• High-temperature sensors


Develop integrated process

models, sensors, and diagnostics

to reduce process variations,

improving tolerances

and efficiencies

R&D PRIORITY

LOW HIGH

MARKET GROWTH

PRODUCTIVITY

TIME COMPRESSION

QUALITY

HUMAN RESOURCES

ENERGY/ENVIRONMENT

Taking advantage of significant advances in modeling, sensors,

controls, diagnostics, and information technologies will help

PM companies get the most out of their capital investments

and process configurations. Because the PM industry is

becoming more capital-intensive, measures companies can take

to improve productivity or time-to-market using existing

investments are crucial to success. Additionally, enhancements

in process modeling and control can help reduce variations in

the process, and thus improve dimensional tolerances and

overall process efficiencies. Such improvements have the

potential to lead to significant cost savings, increasing the value

of PM components to their customers.

2

2

2

• Model verification• Process and parameter definition(including sensor needs)

• Sensor technology application• Test-bed provision• Spark research interest• Elimination of disconnect betweenexisting work in labs/academia andindustrial applications

• National laboratories (softwaredevelopment)

• Provide national facility (e.g.,DOE lab)

• Universities• Sensor manufacturers• Software companies• CTC• MPIF, CISP, PMRC, and otherindustry groups facilities verticalcollaboration among PM

• Vertical collaboration betweencompanies and end-users



2

DESCRIPTION

IMPACT ON GOALS

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ENERGY/ENVIRONMENT

• Data development• Establishment of safe handlingprocesses

• Material test specimen production• Testing methods development

TIME COMPRESSION

HUMAN RESOURCES

• Thermodynamic properties• Metallography• Particle properties/characteristics

MARKET GROWTH

PRODUCTIVITY

QUALITY

LOW


IMPLEMENTATION

HIGH

• Static and dynamic mechanicalproperties

• Chemical properties• Corrosion properties

• NIST• National laboratories• Thermophysical data development• Information repository• Regulator for safe handling• Reference for testing standards

• Universities• Non-governmental organizationsas information repositories

• ASTM• CPMT• PMRC• Other industries- Ceramics- Polymers and chemical companies- Etc.

• Handling and safetyconsiderations

• Unknown/other aspects ofnovel materials (e.g.,biological, etc.)


Understanding the relationships between material

properties, microstructure, and component performance is

crucial for component manufacturers and designers alike to

be able to optimize a specific material or design. Particularly

as new materials and material combinations are introduced

into the PM material portfolio, these relationships between

properties and performance must be well understood and

characterized. The data must be readily accessible — such

data can be of significant use when convincing customers to

consider PM components as an alternative to current

processes used, but without such data displacing existing

manufacturing processes is difficult.

2

2

Conduct fundamental material

characterization studies for

existing and new materials to

determine properties, structure,

and performance relationships

R&D PRIORITY DESCRIPTION

IMPACT ON GOALS

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ENERGY/ENVIRONMENT

• Resource integration/allocation• New process and technologydevelopment

• Cost-benefit evaluations

TIME COMPRESSION

HUMAN RESOURCES

• Total process automation- production- tooling- handling

MARKET GROWTH

PRODUCTIVITY

QUALITY

LOW


IMPLEMENTATION

HIGH

• Sensors and controls to enableclosed-loop feedback control

• Reduced equipment downtime

• Provide access to nationallaboratory capabilities

• Provide neutral industry-wideplatform for collaboration

• Assistance with risk mitigation

• ASTM• CPMT• PMRC• Universities• Vendors and technology providers

• Improved equipment speed• Modeling of large and smallcomponent production


Current PM processes require production to start and stop

for several reasons, including equipment changeover,

component handling, and maintenance. Such interruptions

in production hinder PM companies in their efforts to push

productivities higher while reducing time to market. Process

variations can also lead to quality variations and efficiency

losses. Working to minimize these interruptions will have

significant impact on several of the industry goals, including

the potential to contribute to market growth by improving

the overall value of PM components to both existing and

potential customers.

2

2

2

Minimize process

interruptions to move

to more continuous

production

R&D PRIORITY DESCRIPTION

IMPACT ON GOALS

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MICROSYSTEMMicrosystem

103

2

** Rotor for the watch industry, weight of part 0.0011 g

* Bearing cap for medical application, weight of part 0.01 g/0.02 g

*** Coaxial plug connection,2 colours/MID technology

Clip for medical application,shot weight 0.037 g

*** Coaxial plug connection,2 colours/MID technology

* Locking wheel for micro-mechanics, weight of part 0.0067 g

** Toothed wheel for the watch industry,weight of part 0.0008 g

Latch for the watch industry,weight of part 0.034 g

0,8mm

Implant for medical application,weight of part 0.0022 g

0,8mm

104

3

Battenfeld Microsystem

clean-room conditions. Micro-form parts with high pre-

cision, low energy consumption, significant weight

reduction, cost optimisation and extremely fast cycling

are the strengths of the Microsystem.

The Battenfeld Microsystem and the customer-spe-

cific system solutions offer secure and straightforward

access to the growing market of microtechnology.

The fully electric Microsystem is Battenfeld's innovative

answer to the growing requirements for the pro-

duction of precision micro-components made of

plastic. This production cell has been conceived spe-

cially for the smallest of components in the one-digit

milligram range. Through our experience over many

years in this field, a complete modular concept has

been developed which enables far-reaching pos-

sibilities for injection molding, handling, testing, pro-

duct documentation and packaging, all this under

* Encoder disc with microstructure

* Horst Scholz GmbH & Co. KG** ROLLA Micro-Synthetics AG

*** Tyco Electronics

105

4

Injection moduleThis unit ensures a stableproduction process withminimum shot weights. Inthis way, sprues and cycletimes are reduced signifi-cantly.

Clean-room module*The complete productionprocess is carried out un-der clean-room conditions.In this way, contaminationof the micro-parts is pre-vented.

Removal and handlingmodule*Each micro-part is kepttrue-to-size and stackedseparately according tocavities.

Tray module*Blister reels or trays protectthe micro-parts stacked bythe handling module fromcontamination and transpor-tation damage.

The module technology of the Battenfeld Microsystem

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Control UNILOG B4Precise process control andthe simplest operation of allmodules as well as completeproduct documentation forquality assurance are themost significant advantages.

Clamping moduleThe stable design guaran-tees an exact plane-parallelmold guidance. Particularattention has been paid tosensitive mold safety.

Swivel moduleThe swivel module enablesparallel functions such asinjection and ejection.Productivity is thereforeincreased.

* Optional modules

Quality monitoring module*Each micro-part is monitoredoptically and separated auto-matically by handling, thus feeding only acceptable micro-parts through to subsequentprocessing.

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With the combination offast servo drives andmechanics the Microsys-tem guarantees extreme-ly short cycle timeswith a drying cycle ofaround 1.5 secs.The system supportsprocessing with mini-mum melt cushion, inaddition the injection of

6

Injection technology

The Microsystem injection unit offers a multitude of innova-tions and new possibili-ties in the highly preciseimplementation of thesmallest shot volumesless than 1.1 cm3.

* Actuating bolts with sprue for the electronics industry, weight of part 0.018 g

Injection up to the splitline allows the smallestsprue volume and thusan optimised supply/parts ratio.

Sprues - Microsystem

unplasticised particles isprevented by thermallyhomogeneous process-ing of minimal injectionvolumes with the high-est reproducibility andprocess control.

Different from tradi-tional standard injectionmolding aggregates

with screw injection, theinjection module of theMicrosystem is built upin three stages. Thisdesign was developedspecially for the highlyprecise processing ofthe minimum injectionmolding volume withhighest reproducibilityand process security.

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and maximum injectionspeed of 760 mm/sec.up to the split line guar-antees short flowpaths with the lowestloss of pressure and an extremely precise injection process. Thedeceleration volume at250 mm/sec. thereforeamounts only 0,002cm3. In particular in referenceto the flow parh relation-

ships and molding preci-sion this gives the mostdecisive advantages.

extruder screw

pressure measuring pistons

shut - off valve

mebering sleeve

machineinjection mold

molded part

sprue

heating

Injection module

The most importantfeatures of the injectionmodule: plasticising bymeans of 14-mm extrud-er screws which enablehomogenous prepara-tion of the raw materialwith the lowest degra-dation. On the basis ofthe universal screwgeometry, all commonstandard granulatesizes can be processed.

For special applicationsa special screw geome-try is available. Highlyprecise dynamic headpressure-controlled pre-dosing with a precisionof 0.001cm3 by meansof servo drive and 5-mm pistons enablesthe highest reproducibil-ity precision. Piston injection bymeans of 5-mm pistons

nozzle

clamping plate

injection pistons

* Horst Scholz GmbH & Co. KG

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Mold clamping dimensions

Dimensions/Final values

Clamping unit

Clamping force kN 50

Opening force kN 10

Tool size max. mm 196 x 156

Min. mold height mm 100

Opening stroke mm 200

Max. daylight between platens mm 300

Ejection force kN 1,2

Ejection stroke mm 30

Dry cycle time sec 1.5

Injection unit

International size designation 3

Extruder screw ø mm 14

Injection pistons ø mm 5

Spec. injection pressure limited to (max.) bar 2500

Theoretical injection volume cm3 1.1

Max. screw speed r/min 300

Screw torque Nm 54

Injection speed mm/s 760

Number of heating zones 3 + 3 WZ

Weight approx. kg 1050

Average consumption kW 2

Current A 32

Compressed air ø13 mm bar 6

Water ø13 mm (max. 6 bar) l/min 0.1 - 3

Machine colours:RAL 5002 ultramarine blueRAL 9006 white aluminiumRAL 5011 steel blue

Technical data

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Customer benefits ofthe Microsystem:

■ customer-specificcomplete solutionsfrom one source

■ process-reliable andcost-optimised pro-duction through opti-mum production pro-cess for micro-parts

■ flexibility throughmodular type of con-struction

■ increase in qualitythrough servo driveand precision pro-duction

■ closed clean-roomproduction cells

■ highest resolution pre-cision and repro-ducibility throughservo-electric drives

Micro-parts

The smallest compo-nents in microtechnol-ogy are scarcely visiblewith the naked eye,however their signifi-cance in telecommuni-cations, the watch in-dustry, medical applica-tion, the automotiveand chemicals indus-tries is increasing dra-matically. The marketdemand for smaller and

smaller componentsmade of plastic hasdeveloped a completelynew area of technologywith the continuousminiaturisation of pro-ducts – the Microsys-tem technology.Battenfeld, as your expe-rienced partner, is con-stantly demonstratingnew innovative solutionsusing the Microsystem.

■ cycle time reductionsof up to 50% possiblebecause of parallelmotion

■ significant reductionof sprue volumesusing piston injectionup to the split line

■ complete documenta-tion of the injectionmolding parts throughintegrated qualityassurance

■ tested and segregatedmicroparts for auto-matic post processingon assembly lines

Optional extensionmodules:

■ 2-colour model■ variable thermal pro-

cess control■ vacuum packages

■ servo-controlled ejec-tors

■ injection compression■ sprue pickers

■ PIM, MIM, CIM, injec-tion molding

■ insert and over-mold-ing technology

■ stock preparation■ increased clamping force■ special screws■ optional interfaces

The advantages of the Battenfeld Microsystem

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Battenfeld GmbHScherl 10 · D-58540 Meinerzhagen

Tel. +49 +2354 72-0 · Fax +49 +2354 [email protected]

Battenfeld Kunststoffmaschinen Ges.m.b.H.Wiener Neustädter Straße 81 · A-2542 KottingbrunnTel. +43 +2252 404-0 · Fax +43 +2252 404-7002

[email protected]

www.battenfeld.com BM

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