Replication of micro-structured surfaces by integrating AM with PIM

Alberto Basso*, Macarena Mendez Ribo, Simon Emil Christensen, Peter Kjeldsteen, Peter Valler, David Bue Pedersen, Yang Zhang

*Corresponding author for this work

Research output: Contribution to conferenceConference abstract for conferenceResearchpeer-review

Abstract

3DIMS, 3D-Printing Integrating Manufacturing System, is a process that couples additive manufacturing (AM) with powder injection moulding (PIM). This process allows to overcome some limitations of the conventional injection moulding process such as: high tooling cost, geometrical constrains and failure to manufacture customized parts. This novel process chain works as follows: a thin wall mould is fabricated with a vat-photopolymerisation AM machine, then the mould is filled with a slurry made of metal or ceramic powders and a binder system, after that the mould is dissolved and the part is debinded and sintered. Due to the numerous steps in the manufacturing chain, there are multiple sources of uncertainties and accumulated errors. This work presents an extensive description of this process chain focusing on the geometrical deviation for each step of the process in order to correct and compensate them at the beginning of the chain. The quality of the replication will be evaluated by investigating the geometrical displacement of micro-features on the surface, using an Olympus Lext confocal microscope. Special attention is paid to micro-structured surfaces due to their ability to give new functions to the final part. An investigation on the feasibility to reproduce a close array of micro-pyramids will be carried out in order to produce a part with optical functionalities. The final aim of this investigation is to evaluate and quantify how each stage of the process chain affects the final part and its micro-structure, to verify the possibility to use the 3DIMS process to reproduce objects with functional surfaces.
Original languageEnglish
Publication date2020
Number of pages1
Publication statusAccepted/In press - 2020
Eventeuspen's 20th International Conference & Exhibition - Geneva, Switzerland
Duration: 8 Jun 202012 Jun 2020

Conference

Conferenceeuspen's 20th International Conference & Exhibition
CountrySwitzerland
CityGeneva
Period08/06/202012/06/2020

Keywords

  • Additive manufacturing technology
  • Powder injection moulding
  • Micro-structured surfaces
  • Functional surfaces

Cite this

Basso, A., Mendez Ribo, M., Christensen, S. E., Kjeldsteen, P., Valler, P., Pedersen, D. B., & Zhang, Y. (Accepted/In press). Replication of micro-structured surfaces by integrating AM with PIM. Abstract from euspen's 20th International Conference & Exhibition , Geneva, Switzerland.
Basso, Alberto ; Mendez Ribo, Macarena ; Christensen, Simon Emil ; Kjeldsteen, Peter ; Valler, Peter ; Pedersen, David Bue ; Zhang, Yang. / Replication of micro-structured surfaces by integrating AM with PIM. Abstract from euspen's 20th International Conference & Exhibition , Geneva, Switzerland.1 p.
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abstract = "3DIMS, 3D-Printing Integrating Manufacturing System, is a process that couples additive manufacturing (AM) with powder injection moulding (PIM). This process allows to overcome some limitations of the conventional injection moulding process such as: high tooling cost, geometrical constrains and failure to manufacture customized parts. This novel process chain works as follows: a thin wall mould is fabricated with a vat-photopolymerisation AM machine, then the mould is filled with a slurry made of metal or ceramic powders and a binder system, after that the mould is dissolved and the part is debinded and sintered. Due to the numerous steps in the manufacturing chain, there are multiple sources of uncertainties and accumulated errors. This work presents an extensive description of this process chain focusing on the geometrical deviation for each step of the process in order to correct and compensate them at the beginning of the chain. The quality of the replication will be evaluated by investigating the geometrical displacement of micro-features on the surface, using an Olympus Lext confocal microscope. Special attention is paid to micro-structured surfaces due to their ability to give new functions to the final part. An investigation on the feasibility to reproduce a close array of micro-pyramids will be carried out in order to produce a part with optical functionalities. The final aim of this investigation is to evaluate and quantify how each stage of the process chain affects the final part and its micro-structure, to verify the possibility to use the 3DIMS process to reproduce objects with functional surfaces.",
keywords = "Additive manufacturing technology, Powder injection moulding, Micro-structured surfaces, Functional surfaces",
author = "Alberto Basso and {Mendez Ribo}, Macarena and Christensen, {Simon Emil} and Peter Kjeldsteen and Peter Valler and Pedersen, {David Bue} and Yang Zhang",
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note = "euspen's 20th International Conference & Exhibition ; Conference date: 08-06-2020 Through 12-06-2020",

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Basso, A, Mendez Ribo, M, Christensen, SE, Kjeldsteen, P, Valler, P, Pedersen, DB & Zhang, Y 2020, 'Replication of micro-structured surfaces by integrating AM with PIM', euspen's 20th International Conference & Exhibition , Geneva, Switzerland, 08/06/2020 - 12/06/2020.

Replication of micro-structured surfaces by integrating AM with PIM. / Basso, Alberto; Mendez Ribo, Macarena; Christensen, Simon Emil; Kjeldsteen, Peter ; Valler, Peter; Pedersen, David Bue; Zhang, Yang.

2020. Abstract from euspen's 20th International Conference & Exhibition , Geneva, Switzerland.

Research output: Contribution to conferenceConference abstract for conferenceResearchpeer-review

TY - ABST

T1 - Replication of micro-structured surfaces by integrating AM with PIM

AU - Basso, Alberto

AU - Mendez Ribo, Macarena

AU - Christensen, Simon Emil

AU - Kjeldsteen, Peter

AU - Valler, Peter

AU - Pedersen, David Bue

AU - Zhang, Yang

PY - 2020

Y1 - 2020

N2 - 3DIMS, 3D-Printing Integrating Manufacturing System, is a process that couples additive manufacturing (AM) with powder injection moulding (PIM). This process allows to overcome some limitations of the conventional injection moulding process such as: high tooling cost, geometrical constrains and failure to manufacture customized parts. This novel process chain works as follows: a thin wall mould is fabricated with a vat-photopolymerisation AM machine, then the mould is filled with a slurry made of metal or ceramic powders and a binder system, after that the mould is dissolved and the part is debinded and sintered. Due to the numerous steps in the manufacturing chain, there are multiple sources of uncertainties and accumulated errors. This work presents an extensive description of this process chain focusing on the geometrical deviation for each step of the process in order to correct and compensate them at the beginning of the chain. The quality of the replication will be evaluated by investigating the geometrical displacement of micro-features on the surface, using an Olympus Lext confocal microscope. Special attention is paid to micro-structured surfaces due to their ability to give new functions to the final part. An investigation on the feasibility to reproduce a close array of micro-pyramids will be carried out in order to produce a part with optical functionalities. The final aim of this investigation is to evaluate and quantify how each stage of the process chain affects the final part and its micro-structure, to verify the possibility to use the 3DIMS process to reproduce objects with functional surfaces.

AB - 3DIMS, 3D-Printing Integrating Manufacturing System, is a process that couples additive manufacturing (AM) with powder injection moulding (PIM). This process allows to overcome some limitations of the conventional injection moulding process such as: high tooling cost, geometrical constrains and failure to manufacture customized parts. This novel process chain works as follows: a thin wall mould is fabricated with a vat-photopolymerisation AM machine, then the mould is filled with a slurry made of metal or ceramic powders and a binder system, after that the mould is dissolved and the part is debinded and sintered. Due to the numerous steps in the manufacturing chain, there are multiple sources of uncertainties and accumulated errors. This work presents an extensive description of this process chain focusing on the geometrical deviation for each step of the process in order to correct and compensate them at the beginning of the chain. The quality of the replication will be evaluated by investigating the geometrical displacement of micro-features on the surface, using an Olympus Lext confocal microscope. Special attention is paid to micro-structured surfaces due to their ability to give new functions to the final part. An investigation on the feasibility to reproduce a close array of micro-pyramids will be carried out in order to produce a part with optical functionalities. The final aim of this investigation is to evaluate and quantify how each stage of the process chain affects the final part and its micro-structure, to verify the possibility to use the 3DIMS process to reproduce objects with functional surfaces.

KW - Additive manufacturing technology

KW - Powder injection moulding

KW - Micro-structured surfaces

KW - Functional surfaces

M3 - Conference abstract for conference

ER -

Basso A, Mendez Ribo M, Christensen SE, Kjeldsteen P, Valler P, Pedersen DB et al. Replication of micro-structured surfaces by integrating AM with PIM. 2020. Abstract from euspen's 20th International Conference & Exhibition , Geneva, Switzerland.