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Process chain development for the rapid prototyping of microstructured polymer, ceramic and metal parts: composite flow behaviour optimisation, replication via reaction moulding and thermal postprocessing

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Abstract

Different variants of reaction moulding techniques exploiting the rapid light-induced photopolymerisation of reactive resins are widely used in microsystem technologies for the fabrication of plastic components or for rapid prototyping (RP) purposes. In this paper, the further development of micro reaction moulding with respect to a rapid prototyping of ceramic and metal parts will be described. As in powder injection moulding, the process sequence binder–filler–formulation, replication, debinding and sintering has to be passed. The mould filling and, hence, the accurate reproduction of surface details depend strongly on the composite’s viscosity, which is a function of the filler load. Especially, an improved process control of the composite formation prior to moulding and the thermal debinding is crucial for the realisation of microstructured ceramic or metal parts. The development of the whole process chain and some examples will be presented.

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Authors and Affiliations

  1. Institut f. Materialforschung III, Forschungszentrum Karlsruhe, 76021, Karlsruhe, Germany

    Thomas Hanemann & Juergen Hausselt

  2. Laboratory for Materials Process Technology, Department of Microsystems Engineering (IMTEK), Albert-Ludwigs-University Freiburg, Georges-Koehler-Allee 102, 79110, Freiburg, Germany

    Thomas Hanemann, Kirsten Honnef & Juergen Hausselt

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  1. Thomas Hanemann
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  2. Kirsten Honnef
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  3. Juergen Hausselt
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Correspondence to Thomas Hanemann.

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Hanemann, T., Honnef, K. & Hausselt, J. Process chain development for the rapid prototyping of microstructured polymer, ceramic and metal parts: composite flow behaviour optimisation, replication via reaction moulding and thermal postprocessing. Int J Adv Manuf Technol 33, 167–175 (2007). https://doi.org/10.1007/s00170-007-0952-9

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  • DOI: https://doi.org/10.1007/s00170-007-0952-9

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