Injection moulding technology of micro-elements from metallic and ceramic micro- and nanopowders

Aim of project
The scientific aim of the project is the elaboration of principles of injection moulding technology of micro-elements from metallic and ceramic micro- and nanopowders. Such microelements with dimensions expressed in microns are more and more widely used in micro-electro-mechanical systems (MEMS). The formation process of micro-elements from micro- and nanopowders by injection significantly differs from injection moulding of micro-elements made of thermoplastics or elements made of powders in macro scale. Moreover, it leads to many new technological problems (difficult to solve) which are not explained in publications or patents. The main issue in the project is the elaboration of a new group of binders for micro-injection and a method of their removal. Special attention is paid to rheological properties optimization of powder-binder feedstock in terms of micro-element homogeneity and shape or detail mapping. The micro-injection moulding process is treated with particular attention. The infl uence of process parameters, i.e. injection pressure, feedstock temperature, form temperature, injection cycle and air evacuation from the form cavity on the quality of green micro-parts is defi ned. A crucial issue in the research will be the influence of sintering conditions, i.e. temperature, time and atmosphere on mechanical properties, dimension accuracy and surface state of the micro-elements from micro- and nanopowders.

Expected results
The elaboration of the main principles of the injection moulding technology of micro-elements from micro- and nanopowders will be the first result of the project. The second result will be elaboration of design rules for injection equipment and micro-forms. The research results will be published in scientific journals and presented at national and international conferences. Moreover, results of technological importance will constitute know-how and will be claimed in patents. Some scientific results will be used in a Ph.D. dissertation of one of the members of the research project group.