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PIM is a technique for manufacturing miniature high-precision metallic or ceramic components. In PIM, a metallic or ceramic powder is first blended with a binder, then injection molded, processed to remove binder components, and sintered.
PIM was developed in the U.S. during the 1970s as an advanced approach to powder metallurgy for manufacturing metal components; the technique combined conventional methods of powder metallurgy with injection-molding techniques for plastics. The traditional approach to powder metallurgy, known as press molding, involved inserting metal powders into molds and could only produce components with relatively simple shapes. In contrast, PIM fabricates metal components according to the same principles used in injection molding, allowing mass production of complex-shaped components.
Among the various types of resin used as PIM binders, polyacetal (also known as polyoxymethylene or POM) has a number of particularly valuable properties: it is easily processed, offers high dimensional stability and high mechanical strength, and exists as a crystalline resin with many physical properties that remain stable over a range of temperatures extending up to the melting point. These properties of POM make it the primary choice for injection modeling of precision resin components such as gears—and carry over directly to the PIM domain when POM is used as a binder.
Asahi Kasei offers suitable binder products for both catalytic debinding and thermal debinding in powder injection molding (PIM). In addition to binder resins for catalytic debinding, we have developed an all-in-one binder suitable for heat degreasing in metal injection molding (MIM).
All-in-one binder for thermal debinding in MIM PT120
All-in-one binder for thermal debinding in MIM: TENAC™-P PT120
TENAC™-P PT120 is a grade developed as an All-in-one binder suitable for thermal debinding in metal injection molding(MIM).
All-in-one binder for thermal debinding in MIM: TENAC™-P PT120
Using our alloying technology, multiple types of resins are aggregated and dispersed to reduce voids and residues in sintered parts.
This binder is suitable for thin shaped parts and medical parts.
Comparison of void rario between TENAC™-P PT120 and general binder
As shown in the table below, sintered compacts made with TENAC™-P PT120 have high mechanical properties. High quality sintered compacts can be obtained with little variation in mechanical strength.
Mechanical properties (after sintering)
For more information, please contact us.
If you require more detailed information or samples of TENAC™-P TT120, please contact us from below.
Polyacetal copolymer for catalytic debindingFF520 / FF52P
For catalytic debinding in PIM: TENAC™-C FF520 / FF52P
TENAC™-C FF520 and FF52P are ultra-high fluidity polyacetal copolymers developed as binders suitable for catalytic debinding in powder injection molding (PIM).
Polyacetal (POM) is commonly used as a resin constituent of PIM binders due to the high strength of POM itself and its ability to decompose with no residue under application of acid or heat.
TENAC™-C FF520 and FF52P combine the superior mechanical properties of POM with the advantage of ultra-high flow.
General Properties of TENAC™-C FF520 and FF52P and each resin
Item
Test
Methods
Unit
TENAC™-C FF52P
TENAC™-C FF520
TENAC™-C 7520
HDPE*
PP*
Meltmass flow rate (190℃, 2.16kg)
ISO 1133
g/10min
120
120
30
40
75 (at 230℃)
Density
ISO 1183
g/cm3
1.41
1.41
1.41
0.96
0.90
Melting point
DSC
℃
165
165
165
133
162
Incineration residue
TGA 500℃, under N2
%
0
0
0
0.5
0
Modulus of elasticity
in tension
ISO 527-1
MPa
2840
2840
2800
1000
1400
Elastic modulus in
bend
ISO 178
MPa
2810
2810
2600
1000
1300
Charpy impact strength （notched）
ISO 179
kJ/m2
3
3
5
2.5
2
Deflection temperatureunder load (0.45MPa)
ISO75
℃
156
156
156
67
100
Shape
–
–
Powder d50≒500㎛
Pellet
Pellet
Pellet
Pellet
emarks
Ultra-high flow
Ultra-high flow
Ultra-high flow
Reference
value
Reference
value
*Indicates the reference values for the grades used in PIM.
Sintered ISO2740 dumbbell fabricated using TENAC™-C FF520 (unpolished)
For more information, please download slides
We hope you will consider Asahi Kasei’s FF520 / FF52P as ideal match for your design needs. For more information, please refer to the slides available from the download link below. TENAC™-C FFF520 / FF52P as ideal match for your design needs. For more information, please refer to the slides available from the download link below.
Powder injection molding (PIM) related information
The PIM Process
PIM encompasses both metal injection molding (MIM), based on metallic powders, and ceramic injection molding (CIM), based on ceramic powders; the both processes are nearly identical in practice.
A typical PIM process, here assuming the use of a metallic powder (MIM) as an example, proceeds as follows.
First, the metallic powder is blended with a binder (plastic + wax) to yield a uniform mixture, which is compounded into feedstock with good formability properties. The pelletized feedstock is then molded by an injection-molding machine, just like typical plastics. The resulting molding parts are heated and treated with solvents, catalysts, and other agents to remove binders, then finally sintered in a furnace to yield high-precision metal components. The molding parts obtained immediately following injection molding contain some concentration of binder resins, but these components are eliminated by the binder-removal and sintering steps, ultimately producing metallic bodies with complicated three-dimensional shapes similar to that of plastic injection molding.
Features of PIM
PIM is a processing technique capable of addressing a broad and expanding range of needs, including the production of precision instruments, electrical and communication devices, automotive components, and medical devices. PIM essentially forms metallic components via the same procedure used to manufacture plastics and has the following key features.
Capable of manufacturing high-precision components with complicated shapes
Allows high flexibility in the choice of metallic materials
Excellent for mass production with minimal variation in quality
No need to remove shavings, or for other post-processing steps
Restricted in practice to fabrication of small components due to difficulties in handling larger bodies
Resins used as PIM binders
Resins used as PIM binders must satisfy several practical requirements.
Resins must blend with metal or ceramic powders to yield uniform mixtures (for feedstocks).
Feed stocks must have good processing and formability properties.
PT120
