scholarly journals Precision Mold of Prototype Titanium Orthopedic Implant using Metal Injection Molding Approach

2020 ◽  
Vol 11 (3) ◽  
pp. 487-495
Author(s):  
Haruman Wiranegara ◽  
◽  
Muhammad Nauval Fauzi ◽  
Shinta Virdhian
Keyword(s):  
Injection Molding ◽  
Raw Materials ◽  
Flow Simulation ◽  
Orthopedic Implants ◽  
Design Flow ◽  
Metal Injection Molding ◽  
Injection Process ◽  
Literature Reviews ◽  
Develop Technology ◽  
Feedstock Material

MIDC’s researchers in fulfilling Industry Development Programme have taken a step to develop technology in the design application of orthopedic implants to help suppress the rate of imported medical devices in Indonesia. This research objective was to make a prototype plate for a jawbone connector that meets the geometric specifications with the metal injection molding approach. The jawbone connector plate has a very small size of about 2 mm x 20 mm x 0.5 mm that needs precision mold with certain geometric specifications. MIM approach was used, from the literature reviews that show MIM is the appropriate process for manufacturing implants. The phases of MIM were done according to the standard reference which is making raw materials or feedstock, gatting system design, flow simulation, precision mold producing, mold testing, injection process, debinding, sintering, and mechanical product testing. The results of this study were precision molds with several variants and were test using plastic polypropylene to see the performance of the mold. The researchers then produce the jawbone connector implant using feedstock material. The test result conducted in MIDC successfully shows that the mold can produce shapes that match the required geometry.

Processing of the Fe3Si Alloy from Prealloyed Powder Fe45Si by Metal Injection Molding

2008 ◽  
Vol 591-593 ◽  
pp. 86-90
Author(s):  
Doublas José da Silva ◽  
Aline Silva ◽  
Ricardo Machado ◽  
Paulo A.P. Wendhausen
Keyword(s):  
Chemical Composition ◽  
Injection Molding ◽  
Complex Geometry ◽  
Raw Materials ◽  
Metal Injection Molding ◽  
Vacuum Furnace ◽  
Prealloyed Powder ◽  
Dimensional Precision ◽  
Maximum Permeability ◽  
Better Than

The known process as Metal Injection Molding is derived from the conventional powder metallurgy (M/P) being an alternative for production of parts with complex geometry, great dimensional precision and freedom of chemical composition. The present work has the objective to evaluate the processing of the Fe3Si alloy sintering in the vacuum furnace using as raw materials iron powder carbonyl and prealloyed powder Fe45Si with D90<10-m. Properties of microhardness, density, coercivity, magnetic permeability, and chemical composition was evaluated. The obtained results were compared with what is presented in the literature for parts processed by conventional ways and with parts processed by M/P. A density of 7,620 kg/m3, a coercive field (Hc) of 101.14 A/m, a relative maximum permeability of 5,484 and a residual induction of 1.1 T was achieved by MIM. Comparing with conventional processes (where 100% of densification is reached), the MIM process results were worse, however they were better than P/M.

GRANULAR FLOW SIMULATION FOR METAL INJECTION MOLDING PROCESS

1993 ◽  
Vol 07 (09n10) ◽  
pp. 2047-2056 ◽  
Author(s):  
TAKASHI IWAI ◽  
TATSUHIKO AIZAWA ◽  
JUNJI KIHARA
Keyword(s):  
Injection Molding ◽  
Distinct Element ◽  
Constitutive Relations ◽  
Flow Simulation ◽  
Metal Injection Molding ◽  
Injection Molding Process ◽  
Molding Process ◽  
Polymer Medium ◽  
Powder Particles ◽  
Complex Fluid

Metal Injection Molding treats the complex fluid which consists of thermoplastic tic polymer medium and dense metallic powder suspensions to improve flowability and formability. To understand its fundamental mechanical behavior, it is important to consider powder structures and mechanics precisely. For the analysis of this process, a new granular model is proposed, which is based on the Distinct. Element Method. Each element in this method is constituted by combining a metal powder with a binder (polymer) shell surrounding it. Both elasticity and viscosity for powder particles and binders are only considered in this mixture model as the constitutive relations. Several numerical results have demonstrated the effectiveness and validity of our developed granular modeling to deal with the various phenomena appearing in MIM process.

Injection Molding Flow Simulation of Thin-Walled Slender Tube and Optimization of Combined Cavity

2010 ◽  
Vol 37-38 ◽  
pp. 559-563
Author(s):  
Jun Liu ◽  
Gang Ming Wang ◽  
Bao Shou Sun
Keyword(s):  
Injection Molding ◽  
Cooling System ◽  
Process Analysis ◽  
Flow Simulation ◽  
Manufacturing Cost ◽  
Modeling Technology ◽  
Injection Process ◽  
Thin Walled ◽  
Short Shot ◽  
Molding Flow

Thin-walled slender tubes are produced by injection molding, where there might be defects such as short shot, excessive warpage and uneven temperature distribution. In this paper, injection process analysis was carried out. The 3D modeling technology of Pro/E established a solid model of thin-walled slender tube. MPI (Moldflow Plastics Insight) was used for executing injection molding flow simulation. Gate location and gate number was optimized. Filling system and cooling system of the combined cavity was optimized by analysis of flow, cool and warp. The results can be used for supplying reliable data of mold designing and manufacturing, reducing the engineering mold trial time, decrease the manufacturing cost. The configuration and dimensions of the injection gate can be determined by the computer program before the molds are actually manufactured. The potential defects were forecasted. Therefore, the designers can quickly optimize the mold design.

Flow Behavior Characteristic for Injection Process Using Nano-Yttria Stabilized Zirconia for Micro Metal Injection Molding (µMIM)

2010 ◽  
Vol 44-47 ◽  
pp. 480-484 ◽  
Author(s):  
Farhana Mohd Foudzi ◽  
Norhamidi Muhamad ◽  
Abu Bakar Sulong ◽  
Hafizawati Zakaria
Keyword(s):  
Injection Molding ◽  
Flow Behavior ◽  
Yttria Stabilized Zirconia ◽  
Critical Parameters ◽  
Metal Injection Molding ◽  
Binder System ◽  
Stabilized Zirconia ◽  
Melt Temperature ◽  
Volume Percentage ◽  
Injection Process

Micro metal injection molding (µMIM) prior to conventional plastic injection molding (PIM) has become widely demanding due to its smaller size, more complex geometric surface and time consuming on its product. Metal and ceramic in powder form of various sizes up to µm is mixed with binder system to produce products that meet the requirements. Nano size yttria stabilized zirconia (YSZ) with average particle size of 25nm, was tested both physically and mechanically for its properties before mixing and injection process using several testing such as Scanning Electron Microscopy (SEM), Energy Dispersive X-ray (EDX), pycnometer density, critical powder volume percentage (CPVP) and rheology respectively. Grain shape for YSZ particle is near spherical with the diameter range between 21.2 – 33.5nm while the CPVP shows the highest powder loading was 41.4%. Binder system of 70% palm stearin and 30% polypropylene (PP) was then mixed with YSZ at 37%, 38% and 39% by using internal mixer with roller blade type. By using CPVP of 41.4% as the guideline, mixing was done beyond the critical point until it is capable of becoming the dough mixture and was found that 43% powder loading is the highest loading it can achieved. This dough form of every mixture of powder loading was crushed to obtain pellet size as the feedstock. Rheology test was carried out for each powder loading at 180oC, 190oC and 200oC with the load increasing from 10N to 20N to determine the plastic behavior and best relationship between viscosity (Pa.s) and shear rate (1/s). Dilatant flow behavior for all the powder loadings and smooth data distribution during testing at 180oC was observed respectively. Critical parameters involving in injection process such as mold temperature (oC), melt temperature (oC), pressure (bar) and time (s) was manipulated for every powder loading to obtain the best result with no defects such as shot and flashing. Each critical parameter increased gradually as the powder loading (%) increased. Debinding and sintering process will be carried out to determine the strength and toughness by using micro hardness and micro tensile test respectively.

Preparation and Mechanical Properties of Inconel718 Alloy by Metal Injection Molding

2010 ◽  
Vol 39 (5) ◽  
pp. 775-780 ◽  
Author(s):  
Hu Youhua ◽  
Li Yimin ◽  
He Hao ◽  
Lou Jia ◽  
Tang Xiao
Keyword(s):  
Mechanical Properties ◽  
Injection Molding ◽  
Metal Injection Molding

Application of Taguchi Method for Parameters Optimization in Micro Metal Injection Molding

2011 ◽  
Vol 52-54 ◽  
pp. 244-248
Author(s):  
Haw Pei Li ◽  
Norhamidi Muhamad ◽  
Abu Bakar Sulong ◽  
Heng Shye Yunn ◽  
Hooman Abolhasani
Keyword(s):  
Injection Molding ◽  
Signal To Noise Ratio ◽  
Steel Powder ◽  
Mold Temperature ◽  
Parameters Optimization ◽  
Simultaneous Optimization ◽  
Metal Injection Molding ◽  
Surface Appearance ◽  
Optimal Injection ◽  
Acetate Butyrate

Optimization of injection parameters in Micro Metal Injection Molding (μMIM) was described in this study. Stainless steel powder was mixed with Polyethelena Glycol (PEG), Polymethyl Methacrilate (PMMA) and Cellulose Acetate Butyrate (CAB) to produce feedstock. Design of Experiments (DOE) of Taguchi L-27 (313) orthogonal array technique has been used to investigate the significance and optimal injection molding parameters. The signal-to-noise ratio and analysis of variance (ANOVA) are applied to study the optimum levels and effects of process parameters. Simultaneous optimization to obtain the highest green density and excellent surface appearance was discussed. The result concluded that the mold temperature (D) is the most statistically significant process parameter and its contribution to the best appearance and density is the highest.

Metal injection molding: 3D modeling of nonisothermal filling

2002 ◽  
Vol 42 (4) ◽  
pp. 760-770 ◽  
Author(s):  
Florin Ilinca ◽  
Jean-François Hétu ◽  
Abdessalem Derdouri ◽  
James Stevenson
Keyword(s):  
Injection Molding ◽  
3D Modeling ◽  
Metal Injection Molding
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