Polymethylmethacrylate/polyethyleneglycol-based partially water soluble binder system for micro ceramic injection moulding

In micro powder injection moulding polyethylene-wax binder systems have been widely established for many years enabling the fabrication of dense ceramic or metal micro structured parts. With respect to complete organic moiety removal a solvent debinding step prior to thermal decomposition using hexane as organic solvent has to be applied dissolving the wax prior to thermal decomposition of the polyethylene. The development of environmentally friendly binder systems must consider the substitution of any organic solvent or even the solvent pre-debinding. In this work a modified process chain, starting with a reactive feedstock mixture consisting of a thermally curable methylmethacrylate/polymethylmethacrylate resin, low molecular mass polyethyleneglycol and submicron-sized zirconia as ceramic filler, followed by feedstock polymerization at elevated temperature, pelletizing, injection moulding, debinding and sintering, will be presented. Prior to replication important feedstock properties like temperature and solid load dependent melt viscosity as well as the real solid load was measured guaranteeing a successful mould filling. Two different debinding strategies—with and without water-assisted predebinding—were pursued and the resulting sinter part densities as well as surface qualities were compared. Zirconia test specimen parts with a density around 99 % of the theoretical density could be obtained successfully.