Product novelty 08. September 2023

Injection moulding technologies for special materials

1 / 2
Components CIM
2 / 2
Some materials, which are optimally suited for applications in medical technology due to their property profile, cannot be easily processed by injection moulding.
Our company has taken on the problem and found solutions both for the injection moulding of thin-walled components made of tungsten and for the 2C injection moulding of various types of advanced ceramics.

Diagnostic procedures such as computer tomography require components that allow gamma radiation to pass through from only one direction. These components are characterised by very thin wall areas. Tungsten is the material of choice because of its excellent shielding effect, but the metal is difficult to process. We have succeeded in developing a process for injection moulding tungsten components with very thin walls (0.12 mm). We had to find a binder that creates a flowable tungsten powder for injection moulding. A compound of tungsten and PEEK turned out to be the most suitable.Based on this, we have optimised the process technology so that metal powder with up to 95 % tungsten content can be processed by injection moulding.
Another challenge is the 2-component injection moulding of advanced ceramics. The key point is the different sintering behaviour of the materials. With the University of Stuttgart, we have developed a technology that enables materially bonded joints between different ceramics.
The tasks were finding precisely fitting additives so that the ceramics shrink synchronously during sintering and form a strong bond, building a high-precision injection moulding tool and adapt the production technology.
The innovative process enables the combination of a temperature-resistant structural ceramic and an electrically conductive functional ceramic for applications in high-frequency surgery.

The injection moulding of 2C ceramic parts can be observed live at Fakuma 2023.