Replication processes for metal and ceramic micro parts

To cover the demand for effective manufacturing of metal and ceramic micro components two process technologies are described. The first one can be regarded as a special variant of micro powder injection molding (MicroPIM): inmold-labeling using powder filled feedstocks. Its basic procedures are the backfitting of powder filled foils by an injected PIM-Feedstock and the subsequent co-debinding and co-sintering steps. For example, two-material ceramic parts with microstructured surfaces could be produced and compacted with mostly tight interfaces. The second process conduct combines two-component and insert injection molding with an electroforming process. Since all process steps involved are based on technologies suitable for series production, low product costs per unit will be realistic. Surface qualities and dimensional accuracies are comparable or even better than achieved if applying alternative processes like MicroPIM.