3d Printed Mold for Powder Injection Molding Process

Alberto Basso*, Macarena Mendez Ribo, Anna Halina Danielak, Bolong Yang, Peter Kjeldsteen, Peter Valler, David Bue Pedersen, Yang Zhang

*Corresponding author for this work

Research output: Chapter in Book/Report/Conference proceedingConference abstract in proceedingsResearchpeer-review

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Abstract

Powder injection molding (PIM) is a well-established process that allows mass production of metal and ceramic components with complex geometries. PIM allows eliminating the machining process reducing the overall production cost. This work proposes an innovative process for powder injection molding, enabling the use of this technology also when low production and high geometrical complexity of the part are required. A 3D-printed water-soluble sacrificial mold is used which allows to produce final parts with undercuts and inner channels. In this work an overview of the process chain will be presented, focusing then on the degree of complexity that can be achieved. An analysis of the surface deviation between printed parts and nominal values was carried out showing a deviation of 27 μm. Particular attention was paid to the fabrication of cooling channels, investigating the possibility to print straight pillars. It was possible to produce such a feature when diameters below 0.6 mm or higher than 1.4 mm were used. Moreover, an evaluation of the swelling behavior of the photopolymer during the dissolution process was done.
Original languageEnglish
Title of host publicationProceedings of the Joint Special Interest Group meeting between euspen and ASPE Advancing Precision in Additive Manufacturing (2019)
EditorsA. Bernard, R.K. Leach, D.B. Pedersen, J.S. Taylor
PublisherThe European Society for Precision Engineering and Nanotechnology
Publication date2019
Pages71-74
ISBN (Electronic)978-0-9957751-5-2
Publication statusPublished - 2019
EventJoint Special Interest Group meeting between euspen and ASPE Advancing Precision in Additive Manufacturing - Ecole Centrale de Nantes, Nantes, France
Duration: 16 Sep 201918 Sep 2019

Conference

ConferenceJoint Special Interest Group meeting between euspen and ASPE Advancing Precision in Additive Manufacturing
LocationEcole Centrale de Nantes
CountryFrance
CityNantes
Period16/09/201918/09/2019

Keywords

  • 3D printing
  • Powder Injection Molding
  • Printed Mold Casting
  • Freeform Injection Molding

Cite this

Basso, A., Mendez Ribo, M., Danielak, A. H., Yang, B., Kjeldsteen, P., Valler, P., ... Zhang, Y. (2019). 3d Printed Mold for Powder Injection Molding Process. In A. Bernard, R. K. Leach, D. B. Pedersen, & J. S. Taylor (Eds.), Proceedings of the Joint Special Interest Group meeting between euspen and ASPE Advancing Precision in Additive Manufacturing (2019) (pp. 71-74). The European Society for Precision Engineering and Nanotechnology.
Basso, Alberto ; Mendez Ribo, Macarena ; Danielak, Anna Halina ; Yang, Bolong ; Kjeldsteen, Peter ; Valler, Peter ; Pedersen, David Bue ; Zhang, Yang. / 3d Printed Mold for Powder Injection Molding Process. Proceedings of the Joint Special Interest Group meeting between euspen and ASPE Advancing Precision in Additive Manufacturing (2019). editor / A. Bernard ; R.K. Leach ; D.B. Pedersen ; J.S. Taylor. The European Society for Precision Engineering and Nanotechnology, 2019. pp. 71-74
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abstract = "Powder injection molding (PIM) is a well-established process that allows mass production of metal and ceramic components with complex geometries. PIM allows eliminating the machining process reducing the overall production cost. This work proposes an innovative process for powder injection molding, enabling the use of this technology also when low production and high geometrical complexity of the part are required. A 3D-printed water-soluble sacrificial mold is used which allows to produce final parts with undercuts and inner channels. In this work an overview of the process chain will be presented, focusing then on the degree of complexity that can be achieved. An analysis of the surface deviation between printed parts and nominal values was carried out showing a deviation of 27 μm. Particular attention was paid to the fabrication of cooling channels, investigating the possibility to print straight pillars. It was possible to produce such a feature when diameters below 0.6 mm or higher than 1.4 mm were used. Moreover, an evaluation of the swelling behavior of the photopolymer during the dissolution process was done.",
keywords = "3D printing, Powder Injection Molding, Printed Mold Casting, Freeform Injection Molding",
author = "Alberto Basso and {Mendez Ribo}, Macarena and Danielak, {Anna Halina} and Bolong Yang and Peter Kjeldsteen and Peter Valler and Pedersen, {David Bue} and Yang Zhang",
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Basso, A, Mendez Ribo, M, Danielak, AH, Yang, B, Kjeldsteen, P, Valler, P, Pedersen, DB & Zhang, Y 2019, 3d Printed Mold for Powder Injection Molding Process. in A Bernard, RK Leach, DB Pedersen & JS Taylor (eds), Proceedings of the Joint Special Interest Group meeting between euspen and ASPE Advancing Precision in Additive Manufacturing (2019). The European Society for Precision Engineering and Nanotechnology, pp. 71-74, Joint Special Interest Group meeting between euspen and ASPE Advancing Precision in Additive Manufacturing, Nantes, France, 16/09/2019.

3d Printed Mold for Powder Injection Molding Process. / Basso, Alberto; Mendez Ribo, Macarena; Danielak, Anna Halina; Yang, Bolong ; Kjeldsteen, Peter ; Valler, Peter; Pedersen, David Bue; Zhang, Yang.

Proceedings of the Joint Special Interest Group meeting between euspen and ASPE Advancing Precision in Additive Manufacturing (2019). ed. / A. Bernard; R.K. Leach; D.B. Pedersen; J.S. Taylor. The European Society for Precision Engineering and Nanotechnology, 2019. p. 71-74.

Research output: Chapter in Book/Report/Conference proceedingConference abstract in proceedingsResearchpeer-review

TY - ABST

T1 - 3d Printed Mold for Powder Injection Molding Process

AU - Basso, Alberto

AU - Mendez Ribo, Macarena

AU - Danielak, Anna Halina

AU - Yang, Bolong

AU - Kjeldsteen, Peter

AU - Valler, Peter

AU - Pedersen, David Bue

AU - Zhang, Yang

PY - 2019

Y1 - 2019

N2 - Powder injection molding (PIM) is a well-established process that allows mass production of metal and ceramic components with complex geometries. PIM allows eliminating the machining process reducing the overall production cost. This work proposes an innovative process for powder injection molding, enabling the use of this technology also when low production and high geometrical complexity of the part are required. A 3D-printed water-soluble sacrificial mold is used which allows to produce final parts with undercuts and inner channels. In this work an overview of the process chain will be presented, focusing then on the degree of complexity that can be achieved. An analysis of the surface deviation between printed parts and nominal values was carried out showing a deviation of 27 μm. Particular attention was paid to the fabrication of cooling channels, investigating the possibility to print straight pillars. It was possible to produce such a feature when diameters below 0.6 mm or higher than 1.4 mm were used. Moreover, an evaluation of the swelling behavior of the photopolymer during the dissolution process was done.

AB - Powder injection molding (PIM) is a well-established process that allows mass production of metal and ceramic components with complex geometries. PIM allows eliminating the machining process reducing the overall production cost. This work proposes an innovative process for powder injection molding, enabling the use of this technology also when low production and high geometrical complexity of the part are required. A 3D-printed water-soluble sacrificial mold is used which allows to produce final parts with undercuts and inner channels. In this work an overview of the process chain will be presented, focusing then on the degree of complexity that can be achieved. An analysis of the surface deviation between printed parts and nominal values was carried out showing a deviation of 27 μm. Particular attention was paid to the fabrication of cooling channels, investigating the possibility to print straight pillars. It was possible to produce such a feature when diameters below 0.6 mm or higher than 1.4 mm were used. Moreover, an evaluation of the swelling behavior of the photopolymer during the dissolution process was done.

KW - 3D printing

KW - Powder Injection Molding

KW - Printed Mold Casting

KW - Freeform Injection Molding

M3 - Conference abstract in proceedings

SP - 71

EP - 74

BT - Proceedings of the Joint Special Interest Group meeting between euspen and ASPE Advancing Precision in Additive Manufacturing (2019)

A2 - Bernard, A.

A2 - Leach, R.K.

A2 - Pedersen, D.B.

A2 - Taylor, J.S.

PB - The European Society for Precision Engineering and Nanotechnology

ER -

Basso A, Mendez Ribo M, Danielak AH, Yang B, Kjeldsteen P, Valler P et al. 3d Printed Mold for Powder Injection Molding Process. In Bernard A, Leach RK, Pedersen DB, Taylor JS, editors, Proceedings of the Joint Special Interest Group meeting between euspen and ASPE Advancing Precision in Additive Manufacturing (2019). The European Society for Precision Engineering and Nanotechnology. 2019. p. 71-74