Micro metal powder hot embossing: influence of binder on austenitic stainless steel microparts replicability

ABSTRACT

Micro hot embossing is a well-established technology to produce polymer microdevices and parts. This technology on metal powder/binder feedstocks is an innovator challenge that fits into the sustainable circular economy, being excellent for small series production of precision metallic parts. The powder hot embossing technology is integrated into processes denominated SDS (shaping, debinding, and sintering). This study presents the feasibility of replicating the die features into metallic parts by comparing two binders (Lc and M1). A new binder involves optimising critical parameters during hot embossing to ensure the replication of microdetails and the quality of metallic parts. Comparing the two binders, Lc contributes to the best precision of geometric details, and M1 improves surface quality. The study shows that hot powder embossing is a promising process to manufacture metallic parts with high precision and high-quality geometrical features on a microscale.

KEYWORDS:

• Micro hot embossing
• metal powder
• binder
• feedstocks
• micro metallic parts

Disclosure statement

No potential conflict of interest was reported by the author(s).

Additional information

Funding

The authors acknowledge to Fundação para a Ciência e Tecnologia (FCT) through [doctoral grant SFRH/BD/61840/2009]. This research was sponsored by FEDER funds through the program COMPETE – Programa Operacional Factores de Competitividade – and by national funds through FCT, under the projects Tooling EDGE and [UIDB/00285/2020].

Notes on contributors

E. W. Sequeiros

Elsa W. Sequeiros is an Invited Assistant Professor at the Department of Metallurgical and Materials Engineering, University of Porto, Portugal. After the master's degree (2008) in Metallurgy and Materials Engineering at University of Porto she experienced different fields in Materials Science Engineer: electronics industry, research in joining dissimilar materials by brazing, and powder metallurgy where she received her PhD title (2014) by development of new process – micro powder hot embossing. Her research interests are in micro manufacturing and additive manufacturing of metallic parts with emphasis for mechanical and microstructural characterization.

M. T. Vieira

Maria Teresa Vieira is graduated in Metallurgical Engineering, FEUP, having obtained the Doctorate Degree in Sciences Physique, Orsay, Paris XI University, France (1983) and since 2001 is Full Professor at UC. Currently retired she is a Guest Professor. She has an extensive scientific curriculum in metallic and ceramic materials and additive processes. She had direction positions in: ICEMS (until 2008), CEMUC (2019) and LED&MAT- IPN (up to 2012). Currently, she belongs to CEMMPRE. She has extensive experience in the scientific coordination of national and international I&D projects (>100) in the field of (nano)materials and processing, now essentially in additive manufacturing.

M. F. Vieira

Macnuel F. Vieira received the PhD degree from the University of Porto, Portugal, in 1995. He is an Associate Professor at the Department of Metallurgical and Materials Engineering, University of Porto, Portugal. He is the director at the University of Porto of the Doctoral Program in Advanced Materials and Processing, and the coordinator at INEGI of the Materials and Manufacturing Processes research group of LAETA-Associate Laboratory of Energy, Transports, and Aeronautics. His research interests are centered on mechanical and microstructural characterization of metallic materials, including nanocomposites, and advanced manufacturing processes.