Modeling the Powder Injection Molding Process for Defect-Free, Net-Shape Metal and Ceramic Components.

The Army has identified a need for process innovations that would support the production of components for light weight vehicles out of advanced materials. The use of advanced, lightweight structural materials in vehicular applications presents an opportunity to enhance the effectiveness of Army units. Through more effective energy utilization, fuel will be conserved, which will simplify the logistics of supplying fuel for army vehicles in remote locations. Before these benefits can be realized, proven industrial processes must exist that can be used to economically produce components with complex geometries out of these lightweight materials. Powder injection molding (PIM) is one process that has potential to economically manufacture net shape ceramic, metal, and ceramic matrix composite components to engineering specifications. Unfortunately, process modeling software, which is readily available for injection-molded plastic material, is not available for ceramic or metal materials. During this Phase I project, Lone Peak Engineering (LPE), a commercial injection -molding manufacturer, proposes to develop and test process modeling software for powder injection molding of ceramic and metals.