Keynote Presentation
ESG/Sustainability: A Smart Decision That Goes Beyond Regulatory Compliance
Barton White, Kymera International
Environmental concerns surrounding industrial manufacturing operations have been around for many decades and a focus for most companies; however, only recently has social and governance issues risen to the surface. Yet when “ESG” is discussed, most will still equate it to environmental controls and the “S” and the “G” are largely forgotten. Not only are the social and governance issues of ESG important, but they should also be as critical as the “E”.
The presentation will focus on all three pillars of ESG and that embracing it is not only the right thing to do but is also the smart thing to do as well. Employee satisfaction, operational efficiencies and profitability will benefit all stakeholders. From an environmental perspective we will discuss alternate fuels (is electric really the answer?) and what strategies some companies such as Toyota are embracing. Social and governance strategies such as those implemented by Kymera International will be reviewed that has positioned the company to be a leader in employee satisfaction.
Comparison of MIM & Conventional PM Material Properties, Cost Considerations & Other Business Case Factors for Aftermarket Medical Hardware Component
Jason Osborne, Alpha Precision Group
One way that businesses are reducing new capital costs is by extending the lifespans of installed equipment, thus providing growth potential for the service parts industry made up of original equipment manufacturers (OEM) and aftermarket suppliers. OEM replacement parts offer identical performance and durability as the original factory parts, but they tend to be expensive. One of the many reasons for this is because the manufacturing process best suited for high volume production may not be cost effective for lower volume service needs. On the other hand, aftermarket providers can offer designs, manufacturing processes and materials ranging from low-cost “knock-offs” to high-performance premium solutions. The conventional wisdom is that “you get what you pay for”, but a technically savvy aftermarket supplier can develop a solution that is both cost effective and better performing than the OEM service part. This paper details the performance and cost benefits of an aftermarket MIM medical hardware compared to the OEM stock service component produced from conventional PM.
Metal Injection Molding of Corrosion Resistant Alloys
John Johnson, FAPMI, Novamet/Ultra Fine Specialty Products
Nickel-containing alloys exhibit a combination of strength and resistance to surface degradation that make them useful for many applications, especially in the aerospace and chemical processing industries. Corrosion resistant alloy powders with a wide range of nickel contents can be produced for metal injection molding (MIM) by gas atomization. Examples include 316L, HX, 718, 625, and 270. Sintering conditions to achieve maximum densities for these alloys are reviewed. The mechanical properties of these corrosion resistant alloys processed by MIM are compared to equivalent cast and wrought alloys. Their corrosion resistance is tested in nitric acid, hydrochloric acid, bleach, sodium hydroxide, and sulfuric acid. While 316L and 270 perform well under oxidizing and reducing conditions, respectively, the superalloys, especially 625, perform well in both types of corrosive environments.
Capitalizing on Hybrid Metal 3D Printing to Reduce Tooling Leadtime
Thomas Houle, LUMEX North America, Matsuura Machinery USA
This case-study based presentation focuses on the use of Hybrid Metal AM to reduce the lead time for MIM Tooling while improving product development and time to market scenarios for MIM processors and their customers.
My presentation focuses on the real-world techniques to create tooling which meets traditional manufacturing specifications by using Hybrid Metal AM equipment and materials. I will present multiple real-world examples where tight lead-times were met (or exceeded) by employing a manufacturing process from start to finish developed around the Hybrid Metal AM technology. These examples will highlight the planning, preparation, and philosophy needed to "go-fast" to create useable tooling for product launch and how to capitalize on this tooling platform to transition into production manufacturing.
This presentation will also highlight the expected results and tolerances that can be achieved through Hybrid Metal AM and follow the results through to the production part. In addition, I will present real-world costs associate with implementing this technology with a direct comparison to a traditionally manufactured mold. Finally, I will highlight the manufacturing issues facing MIM Processors as they try and continue to out-source tooling and how the correct implementation of Hybrid Metal AM can address many of the current market concerns.
Several MIM-like Sinter-based AM Processes
Animesh Bose, FAPMI, Optimus Alloys
The metal additive manufacturing (AM) world, over the last decade, has witnessed the proliferation of a host of Sinter-based AM technologies. Most of these technologies separate the geometrical shape formation and the consolidation steps similar to metal injection molded (MIM) process. The resultant properties are similar to MIM and the microstructures are isotropic in nature. Most of these sinter-based AM processes have similarities with metal injection molding (MIM) except for the geometrical shaping step. This presentation will discuss some of these sinter-based AM processes along with their similarities and differences with MIM and highlight some of the advantages and shortcomings of these technology platforms.
Utilizing Metal Injection Molding (MIM) in the Manufacture of a Large Tungsten Heavy Alloy WHA - Firearms Component—Problems and Solutions
Guy Mariella, PTI Tech
Metal Injection Molding-(MIM) is a process that incorporates fine metal powders in a binder system that is then injected into a mold and the molded article is then subsequently de-bound and final sintered. Standard practice would limit this type of processing to parts weighing approximately one hundred grams. The current parts in this study weigh approximately 250 grams.
Tungsten Heavy Alloys are a class of pseudo alloys that are characterized by high specific gravity, good physical properties, and fair machinability. The cost of tungsten powder is high compared to steel powders, machining is relatively expensive compared to aluminum, so material and labor cost savings realized through near net shaped parts using MIM processing is an advantage.
This presentation provides a case study for the production of a Tungsten Heavy Alloy (WHA) firearms component – it looks at initial design, DFM for manufacturing, final production processing problems and solutions that enabled a successful MIM firearms product to be realized.
Development of Water-Atomized Powder for Binder Jet 3D Printers
Keisuke Itotsubo, Epson Atmix
Gas atomized powder is the mainstream powder used in laser and binder jet 3D printers worldwide. Epson Atmix specializes in the production of water atomized powder and recognizes there are few cases of 3D modeling using water atomized powder. Water-atomized powder can be less expensive, but its packing and flowability characteristics may be low compared to gas atomized powder, so spread ability can be difficult. We investigated what kind of modeling characteristics can be obtained by using our own water atomized powder.
Three types of water-atomized powders with different packing and flow properties were studied using a binder jet type 3D printer. Green and sintered parts were analyzed.
Improvements in powder quality showed a direct impact on green and sintered part quality. We believe these advancements can lead to reduced manufacturing costs while maintaining final component quality.
MIM S7 Tool Steel Properties Versus Composition and Processing
Dwight Webster, Advanced Metalworking Practices
Low Alloy and Stainless Steels have long been the most common steel alloy systems to utilize the advantages of metal injection molding as a fabrication technique. As the industry grows, end users continue to seek out and adopt other alloys for their applications. One such alloy is S7 tool steel. Routinely available as a pre-alloy powder, alternate compositions can be built via blending of component powders. An analysis of final properties versus variables of differing feedstock composition and process techniques will be presented.
Machine Setup and Significant Parameters to Adjust the MIM Molding Process
Marko Maetzig, ARBURG GmbH + Co KG
Metal injection molding is a proven process for the production of complex parts for different industrial applications. Within the MIM process, an appropriate molding process is decisive for the production of green parts with high quality.
The presentation will discuss how dedicated features of an injection molding machine can enable this achievement and how the adjustment of the process parameters can significantly improve the production of MIM parts.
Process Optimization Using Simulation Software
Jacob Michaelson, SIGMASOFT Virtual Molding
In this presentation, we will explore the optimization of a MIM process utilizing simulation software. We will evaluate the gate location, cooling layout, temperatures, filling, and packing parameters, while understanding their singular and collective influences on common molding concerns. We’ll also touch on the benefits of using simulation in the process development stage.
A Review of the Attributes and Debinding Methodologies of Binders Utilized in MIM Process
Lane Donoho, Advanced Metalworking Practices
Carbon Foot Print for MIM Furnaces
Maximilian Mungenast, Carbolite Gero GmbH & Co. KG
The "Federal Climate Protection Act" increased carbon dioxide reduction targets on the path to climate neutrality. Thus, the carbon footprint is an essential element of sustainable business management and a valuable instrument for measuring the climate impact of products, services, and organizations. However, for most energy intensive manufacturing processes reliable and comparable data is not available yet. This study reports on the product carbon footprint (PCF) of a typical batch type metal injection moulding (MIM) process. The calculation of the carbon footprint includes the the (metal) injection moulding process of a typical MIM part, catalytic debinding as well as rest debinding and sintering in a batch type MIM furnace for two different kinds of materials.
Metal Additive Manufacturing Complements, not Competes, with Metal Injection Molding
Tibor Gyorfi, Endeavor 3D
Many domestic manufacturers are reshoring their production capabilities and searching for new ways to cut costs and decrease lead times. This paves the way for new processes and technologies that will enable faster product development and just-in-time (JIT) manufacturing solutions. Binder jet Additive Manufacturing (AM) has become a disruptive technology due to the enhanced design freedom and quick iteration benefits. Combine those advantages with the Metal Injection Mold (MIM) process and there are countless ways that the two technologies can complement one another throughout the product lifecycle. In this presentation, Tibor Gyorfi, Metal AM Program Manager at Endeavor 3D, will share his expertise in metal additive manufacturing and why it’s necessary to the future of reshoring production.
- Learn how metal binder jet additive manufacturing works and the design advantages associated
- Compare and contrast binder jet AM with metal injection molding
- Discover several successful use cases when both technologies are combined
Feedstock Development for Metallic Material Extrusion (MEX) of Aluminum Alloys
Margarete Hufnagl, Montanuniversitaet Leoben
Material extrusion with filaments (MEX) is a widely adopted additive manufacturing technology that recently has gained significant interest in producing metal and ceramic parts. When it comes to aluminum and its alloys, there is an overlap between the sintering temperature range and the temperature range at which commonly used "backbone" polymers decompose, providing stability to the initial green parts. Furthermore, aluminum's strong affinity for oxygen mandates the use of specialized sintering methods and alloying strategies. Consequently, achieving low porosity, minimal levels of oxygen and carbon impurities simultaneously poses a significant challenge. To address these issues, feedstocks compatible with the unique requirements of aluminum were created and polypropylene (PP) and high-density polyethylene (HDPE) as backbones were compared. The printed components were subsequently subjected to solvent and thermal debinding. The results showed that both backbones are appropriate to employ in the binder system for MEX of Al alloys.
Dry Ice - A Sustainable Mold Cleaning Solution
Steve Wilson, Coldjet
Topic: Enabling MIM processors to lower their Greenhouse Gas Emissions (ESG) score and support their ESG initiatives.
Session Description: The manufacture of dry ice is in route to a circular economy and using it to clean does not contribute to your GHG emissions score. The C02 utilized for making dry ice is from a Carbon Capture and Utilization process, capturing a by-product from numerous manufacturing processes. It’s an innovative technology that puts recycled C02 to work cleaning molds for a cleaner, healthier plant.
According to both the EPA (Environmental Protection Agency) and CARB (California Air Resource Board), this C02 (now dry ice) is not to be counted a second time at the point of use (mold cleaning). Many MIM processors are actively aligning their manufacturing and maintenance practices with their overall strategy with sustainability goals to remain competitive, resilient and responsible. They have implemented cleaning molds with dry ice to support their ESG initiatives to lower their carbon emission score. Case studies will demonstrate how using dry ice to clean molds not only aligned with corporate sustainability goals profits, but also improved plant efficiency.
Noted Case Studies:
Laszlo Konscek, LEAN Specialist – Electrolux Group (via case study) Stefan Preller, Director of Manufacturing Industrialization (DMI) – A Raymond Group (via case study) Silvio Gachter, Plastics Engineer – Geberit Productions AG (via case study) Joe Pond, Set-Up Supervisor – Silgan Plastics (via case study) Erin Newman, Environmental Scientist – U.S. EPA Office of Atmospheric Programs (via document)
Learning Outcomes:
1. EPA & CARB position statements on cleaning with dry ice and corporate ESG initiatives.
2. Common cleaning applications in the plastics industry to improve profit and efficiency.
3. Working knowledge of the science of how dry ice cleaning works.
Case Study: Utilizing Additive Manufacturing for Rapid Production of MIM Tooling
Tim Will, Ruger Precision Metals
When considering lead times for new MIM parts, the majority of this is often tied up in the mold design/build phase. With typical mold tool production times in the 10-16 week range, there is much to be gained from speeding this process up. This case study covers our progression from building traditional, single-cavity bridge tooling to utilizing additive manufacturing (Hybrid DMLS) to produce multi-cavity production mold tools in-house. This presentation will cover techniques used, lessons learned, opportunities for future advancement, and the overall impact on new MIM part lead times.
Combining Quantitative Fractography Tools and Statistics-Based Models to Estimate Fatigue Life in Porous Metals
Ian Wietecha-Reiman, Penn State University
The implementation of components produced using powder metallurgy techniques in fatigue critical applications in automotive and aerospace applications is hindered by the complex interactions between pore morphology, size, and location. When combined with the increasing demand for accurate fatigue life modeling, more accurate metrics that capture the effects of these pore characteristics are needed to develop improved component certification methodologies. Metrics which capture the complex interactions between these different pore characteristics can be developed by connecting quantitative fractography, such as the Fractal-Topology technique, and non-destructive characterization to predict porosity-limited fatigue life. Quantification of a defect severity criteria through the combination of pore characterization using x-ray computed tomography and fracture surface characterization with advanced statistical analyses represents a path forward for the development of appropriate certification requirements and design guidelines.
Comparison of Four Different Manufacturing Processes (Production Intent MIM, Machined from Millet, Metal AM and MIM Rapid Prototyping) For Pre-Production Prototypes
Jason Osborne, Alpha Precision Group
MIM is a widely accepted, cost-effective and repeatable manufacturing technology for producing high-strength, intricate, tightly-toleranced net-shape components in serial production. Because MIM is a net-shape process, the quality of the mold design and build is crucial to the success of a program launch and ongoing production. Unfortunately, the up-front investment and lead-time for designing and building the typical production intent molds can be significant and may not fit the program budget and delivery requirements for pre-production prototypes. Alternative prototype manufacturing technologies like machining from billets or Metal Additive Manufacturing (MAM) are commonly employed to manage cost and/or timing during the early stages of product development. The prototypes produced from these alternative technologies might not have properties or attributes that fully align with a production intent MIM component, so depending on the intended purpose of the prototypes, this could create noise in an iterative design process. Another manufacturing option for pre-production requirements is MIM rapid prototyping, which uses a proprietary rapid mold manufacturing technology coupled with an otherwise production intent MIM process to produce small quantities of parts with properties identical to a production part. This paper will compare the pros and cons of the four different manufacturing processes (production intent MIM, machined from billet, MAM and MIM rapid prototyping) for pre-production prototypes, and what criteria should be considered in the decision-making process.
Additive Screen Printing: Industrialized AM Technology for Powdered Metals, Ceramics, and Beyond
Eric Bert, Exentis North America
Additive Screen Printing is a new approach to sinter based additive manufacturing for industrial production. Using conventional screen printing techniques combined with high-speed precision optics and industrial handling automation, Exentis has introduced a new, unique technology platform that enables mass production of industrial parts with ultra-fine structures using a wide range of metals, ceramics, and other materials. This presentation will outline how the technology works, its capabilities compared to conventional sinter based PM, MIM/CIM, and other additive techniques, and resulting material properties as well as discuss several successful applications that are in volume production.
More information on Exentis can be found at www.exentis-group.com
Hydrogen Delivery Issues Requires Sintering Atmosphere Options
David E. Wolff, NEL Hydrogen
The North American delivered hydrogen market is undergoing a supply-demand mismatch that is affecting supply reliability. MIM and metal AM require clean atmospheres containing hydrogen for proper sintering and to reach full strength. This presentation will explain the issues underlying supply disruptions, and options for securing reliable hydrogen.
Processing of Mesostructured Stainless Steels Using FFF Technology
Juan Jiménez Alumbreros, Universidad de Castilla-La Mancha (UCLM)
The combination of austenitic and martensitic microstructures in steel composites, arranged in patterns along the mesoscopic scale, has demonstrated an exceptional combination of strength and ductility, not achievable in steels with uniform distribution of multiple phases in their microstructure. Fused Filament Fused Additive Manufacturing (FFF) technology may pave the way for the production of multi-material components, overcoming the limitations of current manufacturing technologies and enabling significant progress in the development of mesostructured steels in parts with complex geometry. Although FFF is still under development and presents several challenges that require attention, this study marks an important milestone by demonstrating the successful fabrication of mesostructured parts by combining austenitic and martensitic steels. The design and production of windable and printable filaments from 316L and 17-4PH has enabled the production of defect-free mesostructured parts, successfully overcoming the challenges inherent to this technique that are analyzed and discussed in this paper. This achievement represents a significant step on the road towards the development of new materials with exceptional and tunable properties through mesostructure design.
Lithography-Based Metal Manufacturing as a Complementary Process to MIM
György Attila Harakály, Incus GmbH
Lithography-Based Metal Manufacturing (LMM) is an additive manufacturing technique that utilizes photopolymerization to create metal components. In this process, metal powder is combined with a light-sensitive binder, and the three-dimensional structure is built layer by layer through light exposure. LMM harnesses the advantages of lithography, including excellent surface finish, precise detailing, and feature resolution, to produce functional metal parts without the need for traditional support structures.
To achieve the final metallic properties, the printed parts, like other sinter-based metal manufacturing methods, undergo a debinding and sintering step. LMM has been developed as a complementary technology to MIM for mass production, providing support for rapid prototyping and swift design iterations. Additionally, it enables the production of complex shapes that would pose challenges for MIM. Consequently, LMM can assist MIM producers in enhancing customer support, streamlining product development, and can also serve as a standalone production technique for a wide variety of functional metal components. Sintered 316L parts produced using LMM exhibit a tensile strength equivalent to parts made using MIM. Furthermore, the average surface roughness (Ra) for as-sintered components is less than 3 µm, dependent on the powder atomization technique. The LMM approach allows for the production of intricate geometries without the risk of material loss during fabrication, making it an economically and environmentally viable method for metal manufacturing.
Metal Manufacturing in Space with Sintering Based Extrusion 3D Printing
Fatou Ndiaye, University of Louisville
In space metal manufacturing in the International Space Station (ISS) from materials sent from earth and also from metal waste generated from food packaging containing aluminum. In this work we present 3D printing with Al and Al6061 via paste 3D printing and sintering approach. We use Al and Al6061 powders to make a paste using a mixture of binder and 3D printing using a custom-built extrusion 3D printer. The printed parts such as density cubes and tensile bars were sintered, and their mechanical properties were studied. This research elucidates the importance of powder characteristics, paste preparation, and sintering conditions that could potentially lead to 3D-printed parts. The need to optimize the composition of the paste and its effect on 3D-printed and sintered parts was essential to study. Furthermore, the study highlights the effect of additives such as magnesium for improving the mechanical properties of sintered aluminum parts.
Physical Characterization Methods for Metal Powders
Jack G. Saad, Micromeritics Instrument Corporation
Anytime a powder is used in a process for a specific purpose, its behavior is often predicted by physical properties of the powder. Determining the physical properties of a metal powder can be used to decide which properties are critical to the performance of the metal injection molding process, as well as the quality of the final product. Samples of stainless steel 316L powder were characterized to determine the following physical properties:
- Specific Surface Area
- Porosity and Pore Size Distribution
- Density
- Particle Size and Size Distribution
The samples of stainless steel 316L powder were at different stages in a process which may modify some physical characteristics of the powder. The difference in the physical characterization data demonstrates the sensitivity of the techniques used and aids in the detection of possible critical physical qualities required to improve performance of the powder and the metal injection molding process.
Towards Binder Jetting of Graphene-Reinforced Copper for Improving Mechanical and Electrical Properties
Kaustubh Deshmukh, Virginia Tech, Department of Mechanical Engineering
In this work, a graphene reinforced pure copper feedstock is prepared by stirring-based process to mix graphene with copper powders. To maximize part densification, bimodal powder mixture is used. EDS reveals uniform distribution of graphene particles as satellites on the copper powders. Powder flowability tests points towards a printable flow character of composite powders. Two sets of parts were fabricated, a control set with homogenous binder distribution throughout the part volume, and another set where binder is selectively placed only around the part shell. “Shell printing” led to lower part shrinkage and improved density and tensile strength compared to control. Shell printing allows adequate green strength for part handling while reducing the pores introduced by binder entrapment during sintering cycle. Compared to the control binder jetting of pure copper, density and tensile strength reduces. This reduction in performance maybe due to the presence of graphene agglomerates and sub-optimal sintering parameters, which limit diffusion and increase porosity in the matrix.
Thermal Conductivity Characterization Using the Hot Disk Method
Artem A. Trofimov, Orton Ceramic Foundation
Both Powder Injection Molding (PIM) and Additive Manufacturing (AM) need to have well understood, accurate, and reliable thermal properties of the materials used in their manufacturing process, since those properties can be used for a variety of purposes, including simulations/modeling, process optimization, quality control, etc.
In this work, Hot Disk Transient Plane Source technique is proposed for thermal characterization because it provides both thermal conductivity and thermal diffusivity from a single measurement (as such, volumetric heat capacity becomes known as well), allows to measure both solid samples and powders, different samples sizes (from a few millimeters and larger), and capable of differentiating between through-plane and in-plane thermal properties.
Previously, the Hot Disk method was applied to MIM tungsten powders, 17-4PH and 316L steel powders, and a variety of green, brown, and sintered parts of these materials. This presentation will take a deeper dive into the fundamentals of the technique, how exactly the method enables thermal characterization, and what benefits it can offer to PIM and AM industries. Potential applications of this technique will be discussed, including fast and easy thermal characterization of powders and feedstocks, characterization of MIM materials used for thermal management (e.g., Cu and Cu-alloys, W-Cu, Mo-Cu), and evaluation of possible anisotropy of AM materials.