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Kuo CC, Pan XY. Development of a Rapid Tool for Metal Injection Molding Using Aluminum-Filled Epoxy Resins. Polymers (Basel) 2023; 15:3513. [PMID: 37688141 PMCID: PMC10490354 DOI: 10.3390/polym15173513] [Citation(s) in RCA: 2] [Impact Index Per Article: 2.0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 07/06/2023] [Revised: 08/10/2023] [Accepted: 08/16/2023] [Indexed: 09/10/2023] Open
Abstract
Metal injection molding (MIM) is a near net-shape manufacturing process combining conventional plastic injection molding and powder metallurgy. Two kinds of injections molds for MIM were developed using conventional mold steel and aluminum (Al)-filled epoxy resins in this study. The characteristics of the mold made by rapid tooling technology (RTT) were evaluated and compared with that of the fabricated conventional machining method through the MIM process. It was found that the service life of the injection mold fabricated by Al-filled epoxy resin is about 1300 molding cycles with the average surface roughness of 158 nm. The mold service life of the injection mold fabricated by Al-filled epoxy resin is about 1.3% that of the conventional mold steel. The reduction in manufacturing cost of an injection mold made by Al-filled epoxy resin is about 30.4% compared with that of the fabricated conventional mold steel. The saving in manufacturing time of an injection mold made by RTT is about 30.3% compared with that of the fabricated conventional machining method.
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Affiliation(s)
- Chil-Chyuan Kuo
- Department of Mechanical Engineering, Ming Chi University of Technology, No. 84, Gungjuan Road, New Taipei City 243, Taiwan
- Research Center for Intelligent Medical Devices, Ming Chi University of Technology, No. 84, Gungjuan Road, New Taipei City 243, Taiwan
- Department of Mechanical Engineering, Chang Gung University, No. 259, Wenhua 1st Road, Guishan District, Taoyuan City 333, Taiwan
- Center for Reliability Engineering, Ming Chi University of Technology, No. 84, Gungjuan Road, New Taipei City 243, Taiwan
| | - Xin-Yu Pan
- Shin Zu Shing Co., Ltd., No. 174, Junying Street, Shulin District, New Taipei City 238, Taiwan
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Basir A, Muhamad N, Sulong AB, Jamadon NH, Foudzi FM. Recent Advances in Processing of Titanium and Titanium Alloys through Metal Injection Molding for Biomedical Applications: 2013-2022. MATERIALS (BASEL, SWITZERLAND) 2023; 16:ma16113991. [PMID: 37297124 DOI: 10.3390/ma16113991] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Grants] [Track Full Text] [Subscribe] [Scholar Register] [Received: 04/16/2023] [Revised: 05/14/2023] [Accepted: 05/23/2023] [Indexed: 06/12/2023]
Abstract
Metal injection molding (MIM) is one of the most widely used manufacturing processes worldwide as it is a cost-effective way of producing a variety of dental and orthopedic implants, surgical instruments, and other important biomedical products. Titanium (Ti) and Ti alloys are popular modern metallic materials that have revamped the biomedical sector as they have superior biocompatibility, excellent corrosion resistance, and high static and fatigue strength. This paper systematically reviews the MIM process parameters that extant studies have used to produce Ti and Ti alloy components between 2013 and 2022 for the medical industry. Moreover, the effect of sintering temperature on the mechanical properties of the MIM-processed sintered components has been reviewed and discussed. It is concluded that by appropriately selecting and implementing the processing parameters at different stages of the MIM process, defect-free Ti and Ti alloy-based biomedical components can be produced. Therefore, this present study could greatly benefit future studies that examine using MIM to develop products for biomedical applications.
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Affiliation(s)
- Al Basir
- Department of Mechanical and Manufacturing Engineering, Faculty of Engineering and Built Environment, Universiti Kebangsaan Malaysia, Bangi 43600, Selangor, Malaysia
| | - Norhamidi Muhamad
- Department of Mechanical and Manufacturing Engineering, Faculty of Engineering and Built Environment, Universiti Kebangsaan Malaysia, Bangi 43600, Selangor, Malaysia
| | - Abu Bakar Sulong
- Department of Mechanical and Manufacturing Engineering, Faculty of Engineering and Built Environment, Universiti Kebangsaan Malaysia, Bangi 43600, Selangor, Malaysia
| | - Nashrah Hani Jamadon
- Department of Mechanical and Manufacturing Engineering, Faculty of Engineering and Built Environment, Universiti Kebangsaan Malaysia, Bangi 43600, Selangor, Malaysia
| | - Farhana Mohd Foudzi
- Department of Mechanical and Manufacturing Engineering, Faculty of Engineering and Built Environment, Universiti Kebangsaan Malaysia, Bangi 43600, Selangor, Malaysia
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Liu C, Lu H, Qin M, Wu H, Zhang Z, He Q, Wang Y, Jia B, Qu X. Effect of powders on aluminum nitride components fabricated by PIM. POWDER TECHNOL 2023. [DOI: 10.1016/j.powtec.2023.118409] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 03/09/2023]
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An Overview of Highly Porous Titanium Processed via Metal Injection Molding in Combination with the Space Holder Method. METALS 2022. [DOI: 10.3390/met12050783] [Citation(s) in RCA: 2] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [Abstract] [Track Full Text] [Subscribe] [Scholar Register] [Indexed: 02/01/2023]
Abstract
In the past two decades, titanium foams have attracted greater interest from the biomedical industry due to their excellent chemical and mechanical biocompatibility when used as biomimetic implants. The porous structure plays an important role in bone adhesion to an implant, allowing its growth into the component. Moreover, the voids reduce the elastic modulus, promoting greater compatibility with the bone, avoiding the stress shielding effect. In this regard, metal injection molding is an attractive process for titanium foams manufacturing due to the high microstructural control and the possibility of producing, on a large scale, parts with complex near-net-shaped structures. In this review, recent discoveries and advantages regarding the processing of titanium powders and alloys via metal injection molding combined with the space holder method are presented. This approach can be used to obtain foams with high biocompatibility with the human body at a microstructural, chemical, and mechanical level.
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Thavanayagam G, Swan J. A new model for predicting the flow properties of Ti-6Al-4V-MIM feedstocks. POWDER TECHNOL 2022. [DOI: 10.1016/j.powtec.2022.117306] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/24/2022]
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6
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Ma R, Chang L, Dong Y, Ye S, Si J, Yao K, Yu P. Magnetic properties of soft magnetic composites fabricated by injection molding of bimodal amorphous Fe73Si11B11C3Cr2 and crystalline Fe50Co50 powders. POWDER TECHNOL 2022. [DOI: 10.1016/j.powtec.2021.11.030] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.5] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/17/2022]
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7
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Fabrication of TiAl alloys turbocharger turbine wheel for engines by metal injection molding. POWDER TECHNOL 2021. [DOI: 10.1016/j.powtec.2021.01.070] [Citation(s) in RCA: 8] [Impact Index Per Article: 2.7] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/21/2022]
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8
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Dehghan-Manshadi A, Yu P, Dargusch M, StJohn D, Qian M. Metal injection moulding of surgical tools, biomaterials and medical devices: A review. POWDER TECHNOL 2020. [DOI: 10.1016/j.powtec.2020.01.073] [Citation(s) in RCA: 22] [Impact Index Per Article: 5.5] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/16/2022]
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9
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Thavanayagam G, Swan J. Optimizing hydride-dehydride Ti-6Al-4V feedstock composition for titanium powder injection moulding. POWDER TECHNOL 2019. [DOI: 10.1016/j.powtec.2019.07.091] [Citation(s) in RCA: 2] [Impact Index Per Article: 0.4] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 10/26/2022]
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10
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Online Rheometry Investigation of Flow/Slip Behavior of Powder Injection Molding Feedstocks. Polymers (Basel) 2019; 11:polym11030432. [PMID: 30960416 PMCID: PMC6473305 DOI: 10.3390/polym11030432] [Citation(s) in RCA: 2] [Impact Index Per Article: 0.4] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 01/10/2019] [Revised: 02/24/2019] [Accepted: 02/27/2019] [Indexed: 11/28/2022] Open
Abstract
Wall slip in the flow of powder injection molding (PIM) compounds can be the cause of unrealistically low viscosity values, and can lead to a failure of flow simulation approaches. Regardless of its importance, it has been considered only scarcely in the rheological models applied to PIM materials. In this paper, an online extrusion rheometer equipped with rectangular slit dies was used to evaluate the slip velocity of commercial as well as in-house-prepared PIM feedstocks based on metallic and ceramic powders at close-to-processing conditions. The tested slit dies varied in their dimensions and surface roughness. The wall-slip effect was quantified using the Mooney analysis of slip velocities. The smaller gap height (1 mm) supported the wall-slip effect. It was shown that both the binder composition and the powder characteristic affect slip velocity. Slip velocity can be reduced by tailoring a powder particle size distribution towards smaller particle fractions. The thickness of the polymer layer formed at the channel wall is higher for water-soluble feedstocks, while in the case of the catalytic polyacetal feedstocks the effect of surface roughness was manifested through lower viscosity at smooth surfaces.
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12
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Harun W, Manam N, Kamariah M, Sharif S, Zulkifly A, Ahmad I, Miura H. A review of powdered additive manufacturing techniques for Ti-6al-4v biomedical applications. POWDER TECHNOL 2018. [DOI: 10.1016/j.powtec.2018.03.010] [Citation(s) in RCA: 80] [Impact Index Per Article: 13.3] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 12/13/2022]
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13
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Harun W, Kamariah M, Muhamad N, Ghani S, Ahmad F, Mohamed Z. A review of powder additive manufacturing processes for metallic biomaterials. POWDER TECHNOL 2018. [DOI: 10.1016/j.powtec.2017.12.058] [Citation(s) in RCA: 110] [Impact Index Per Article: 18.3] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 10/18/2022]
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Thavanayagam G, Swan J. Aqueous debinding of polyvinyl butyral based binder system for titanium metal injection moulding. POWDER TECHNOL 2018. [DOI: 10.1016/j.powtec.2017.11.069] [Citation(s) in RCA: 5] [Impact Index Per Article: 0.8] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 10/18/2022]
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15
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Processing of MIM feedstocks based on Inconel 718 powder and partially water-soluble binder varying in PEG molecular weight. POWDER TECHNOL 2017. [DOI: 10.1016/j.powtec.2017.09.029] [Citation(s) in RCA: 5] [Impact Index Per Article: 0.7] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/22/2022]
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Dehghan-Manshadi A, Bermingham MJ, Dargusch M, StJohn D, Qian M. Metal injection moulding of titanium and titanium alloys: Challenges and recent development. POWDER TECHNOL 2017. [DOI: 10.1016/j.powtec.2017.06.053] [Citation(s) in RCA: 55] [Impact Index Per Article: 7.9] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 10/19/2022]
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Hamidi MFFA, Harun WSW, Samykano M, Ghani SAC, Ghazalli Z, Ahmad F, Sulong AB. A review of biocompatible metal injection moulding process parameters for biomedical applications. MATERIALS SCIENCE & ENGINEERING. C, MATERIALS FOR BIOLOGICAL APPLICATIONS 2017; 78:1263-1276. [PMID: 28575965 DOI: 10.1016/j.msec.2017.05.016] [Citation(s) in RCA: 61] [Impact Index Per Article: 8.7] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Subscribe] [Scholar Register] [Received: 08/08/2016] [Revised: 04/30/2017] [Accepted: 05/04/2017] [Indexed: 01/07/2023]
Abstract
Biocompatible metals have been revolutionizing the biomedical field, predominantly in human implant applications, where these metals widely used as a substitute to or as function restoration of degenerated tissues or organs. Powder metallurgy techniques, in specific the metal injection moulding (MIM) process, have been employed for the fabrication of controlled porous structures used for dental and orthopaedic surgical implants. The porous metal implant allows bony tissue ingrowth on the implant surface, thereby enhancing fixation and recovery. This paper elaborates a systematic classification of various biocompatible metals from the aspect of MIM process as used in medical industries. In this study, three biocompatible metals are reviewed-stainless steels, cobalt alloys, and titanium alloys. The applications of MIM technology in biomedicine focusing primarily on the MIM process setting parameters discussed thoroughly. This paper should be of value to investigators who are interested in state of the art of metal powder metallurgy, particularly the MIM technology for biocompatible metal implant design and development.
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Affiliation(s)
- M F F A Hamidi
- Institute of Postgraduate Studies, Universiti Malaysia Pahang, Lebuhraya Tun Razak, 26300 Gambang, Kuantan, Pahang, Malaysia
| | - W S W Harun
- Green Research for Advanced Materials Laboratory, Human Engineering Group, Faculty of Mechanical Engineering, Universiti Malaysia Pahang, 26600 Pekan, Pahang, Malaysia.
| | - M Samykano
- Structural and Material Degradation Group, Faculty of Mechanical Engineering, Universiti Malaysia Pahang, 26600 Pekan, Pahang, Malaysia
| | - S A C Ghani
- Green Research for Advanced Materials Laboratory, Human Engineering Group, Faculty of Mechanical Engineering, Universiti Malaysia Pahang, 26600 Pekan, Pahang, Malaysia
| | - Z Ghazalli
- Green Research for Advanced Materials Laboratory, Human Engineering Group, Faculty of Mechanical Engineering, Universiti Malaysia Pahang, 26600 Pekan, Pahang, Malaysia
| | - F Ahmad
- Department of Mechanical Engineering, Universiti Teknologi PETRONAS, Malaysia
| | - A B Sulong
- Department of Mechanical & Materials Engineering, Faculty of Engineering & Built Environment, Universiti Kebangsaan Malaysia, 43600 UKM, Bangi, Malaysia
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Lin D, Sanetrnik D, Cho H, Chung ST, Kwon YS, Kate KH, Hausnerova B, Atre SV, Park SJ. Rheological and thermal debinding properties of blended elemental Ti-6Al-4V powder injection molding feedstock. POWDER TECHNOL 2017. [DOI: 10.1016/j.powtec.2016.12.071] [Citation(s) in RCA: 26] [Impact Index Per Article: 3.7] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 10/20/2022]
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20
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Romero A, Herranz G. Development of feedstocks based on steel matrix composites for metal injection moulding. POWDER TECHNOL 2017. [DOI: 10.1016/j.powtec.2016.12.055] [Citation(s) in RCA: 10] [Impact Index Per Article: 1.4] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/30/2022]
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21
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Development and Characterization of a Metal Injection Molding Bio Sourced Inconel 718 Feedstock Based on Polyhydroxyalkanoates. METALS 2016. [DOI: 10.3390/met6040089] [Citation(s) in RCA: 7] [Impact Index Per Article: 0.9] [Reference Citation Analysis] [Track Full Text] [Subscribe] [Scholar Register] [Indexed: 11/16/2022]
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22
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Royer A, Barriere T, Gelin J. The degradation of poly(ethylene glycol) in an Inconel 718 feedstock in the metal injection moulding process. POWDER TECHNOL 2015. [DOI: 10.1016/j.powtec.2015.07.032] [Citation(s) in RCA: 14] [Impact Index Per Article: 1.6] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/24/2022]
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