Title: Limits and challenges of manufacturing micro moulds

Authors: Volker Schulze, Patricia Weber, Marco Deuchert, Sebastian Haupt, Christoph Ruhs, Andreas Kienzler

Addresses: wbk Institute of Production Science, Center for Materials Processing (ZMB), University Karlsruhe (TH), Kaiserstr. 12, 76131 Karlsruhe, Germany. ' wbk Institute of Production Science, Center for Materials Processing (ZMB), University Karlsruhe (TH), Kaiserstr. 12, 76131 Karlsruhe, Germany. ' wbk Institute of Production Science, Center for Materials Processing (ZMB), University Karlsruhe (TH), Kaiserstr. 12, 76131 Karlsruhe, Germany. ' wbk Institute of Production Science, Center for Materials Processing (ZMB), University Karlsruhe (TH), Kaiserstr. 12, 76131 Karlsruhe, Germany. ' wbk Institute of Production Science, Center for Materials Processing (ZMB), University Karlsruhe (TH), Kaiserstr. 12, 76131 Karlsruhe, Germany. ' wbk Institute of Production Science, Center for Materials Processing (ZMB), University Karlsruhe (TH), Kaiserstr. 12, 76131 Karlsruhe, Germany

Abstract: Due to the ongoing miniaturisation in industrial sectors like automotive, electronics or medical, the development of new manufacturing processes which are suitable for micro system technologies gains more and more importance. The miniaturisation of components leads to challenges in the manufacturing of micro parts. One application area is the manufacturing of moulds for the micro powder injection moulding (μPIM) process. This process requires good surface qualities and a sufficient demoulding behaviour of the moulds. Micro milling, micro electrical discharge machining (μEDM) and micro laser beam machining (μLBM) are appropriate processes for the manufacturing of micro structures in different materials. Abrasive micro peening can be used for further precision treatment. Depending on the desired structure a single process or the combination of several processes has to be chosen to obtain superior surface qualities of the moulds. This paper deals with challenges and limits of the manufacturing processes among others exemplified on a gearwheel mould.

Keywords: micromoulds; micromachining; micromanufacturing; micromilling; electrical discharge machining; EDM; micro-EDM; electro-discharge machining; laser beam machining; LBM; laser ablation; Nd:YAG lasers; hybrid machining; surface treatment; abrasive micro peening; nanotechnology; injection moulding; nanomanufacturing; microstructure; surface quality; gearwheel moulds.

DOI: 10.1504/IJNM.2010.034782

International Journal of Nanomanufacturing, 2010 Vol.6 No.1/2/3/4, pp.176 - 189

Published online: 22 Aug 2010 *

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