Co-Processing Metal Injection Molding for Complex Geometries

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Solution Overview

Problem

The existing metal injection molding (MIM) process faces challenges in manufacturing complex shaped parts with certain geometries, such as hollow centers or porous materials, limiting its ability to produce components with desired characteristics.

Innovation Solution

A method involving co-processing of two or more sub-components using metal injection molding, where feedstocks are prepared, molded, debound, and sintered together to form an integral assembled component with specific geometries and material properties, allowing for the creation of complex shapes and reduced densities.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If traditional MIM process is used to manufacture complex shaped parts, then manufacturing cost is reduced, but ability to produce parts with certain geometries (hollow centers, porous structures) is limited

Engineering Contradiction:

Improveability to produce complex geometriesVSAvoidmanufacturing process complexity

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

The invention divides the manufacturing process into multiple stages by introducing sacrificial components that are molded separately and then integrated into the main component during the MIM process. This segmentation allows complex geometries (hollow centers, porous structures) to be created by removing the sacrificial material after sintering, while maintaining the cost-effectiveness of the overall MIM process.

Inventive Principle:

Principle #1Segmentation

2Reliability

If density is reduced to create porous structures and hollow voids, then component performance is improved, but manufacturing precision is compromised

Engineering Contradiction:

Improvecomponent performanceVSAvoiddensity control

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

The invention uses sacrificial components as intermediaries to create the desired porous structures and hollow voids. These sacrificial components are molded with precise dimensions and integrated into the main component before sintering. After sintering, the sacrificial material is removed, leaving behind controlled porous structures and hollow voids with precise geometries, thus maintaining manufacturing precision while achieving the desired density reduction for improved component performance.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Productivity

If multiple separate components are manufactured and assembled, then manufacturing flexibility is maintained, but production time increases

Engineering Contradiction:

Improveproduction timeVSAvoidassembly complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The invention merges multiple manufacturing operations into a single integrated MIM process. The main component and sacrificial components are molded separately but then assembled and sintered together in one continuous process, creating an integral assembled component. This eliminates the need for separate assembly operations after sintering, significantly reducing production time while maintaining the flexibility to design complex integrated structures that would be difficult to achieve with traditional single-piece MIM.

Inventive Principle:

Principle #5Merging (Combining)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

Enables the production of medical components with complex geometries and reduced densities, such as hollow voids and graded density structures, improving manufacturing capabilities and component performance.

Implementation Method 1

This feedstock is then injected into a mold to produce a 'green part' that takes the shape of the mold

Methodology Applied

Scientific EffectInjection molding:

Implementation Method 2

Once formed, the green part is removed from the mold, allowed to rest for a period of time and is then 'debound', meaning the binder is removed from the part

Methodology Applied

Scientific EffectDebinding:

Implementation Method 3

The debound part is then sintered at a high temperature to cause the particles of the material powder to partially melt, bond together and form the completed part

Methodology Applied

Scientific EffectSintering: Sintering

Data Source

PatentUS10159574B2Method for co-processing components in a metal injection molding process, and components made via the same

Publication Date: 2018.12.25 HOWMEDICA OSTEONICS CORP

AI summary

A method comprising molding a first component from a first feedstock comprising a first material powder and a first binder, molding a second component from a second feedstock comprising a second material powder and a second binder, placing the first component and the second component in physical communication with each other in order to form an assembled component, removing the first binder and the second binder from the assembled component and performing a sintering operation on the assembled component so as to bond the first component and the second component together.