Micro-Moulding. Battenfeld Injection Molding. Microsystem. the innovative solution for microprecision parts. Part volume:
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1 Micro-Moulding Battenfeld Injection Molding Part volume: 0,00065 cm³ (Shot volume 0,07 cm³) the innovative solution for microprecision parts
2 Micro-Moulding Moulding the innovative system solution for moulding of micro precision parts Too small for conventional injection moulding machines Quelle/Source: Battenfeld, Horst Scholz GmbH & Co.KG
3 contents 1. Market 2. Concept Microsystem 3. Injection process 4. Basic modules 5. Options 6. Mould technology 7. Materials 8. Applications 9. Benefits / Summary
4 Market
5 market trend: reduction of part weights < 0.1 g micro precision parts Why downsizing products? less weight smaller dimensions with more functions less energy consumption new products needs high precision
6 which markets need micro parts Automotive Computer Telecommunication Connectors Electronics Micro-equipment Medical technology Sensors Micromechanics Optics Watches Glass fiber conductors Microstructure Precise suppliers Special materials Institutes, Universities Micro switch, sensors, ABS-Systems Head of an ink-jet printer Mobile phone, MID Plug connectors, opto couplers Micro parts on circuit boards Valve technology Hearing aids, implants, biodegradable Airbag sensors, sensor disk Micro motors, rotors Lenses, displays Gear wheels, latches, micro transmissions Ferrules, connectors Lab on the Chip, data carrier Various parts PIM ( MIM / CIM ), PTFE Material-, technology research Quelle/Source:Battenfeld
7 Microsystem world market expectations MST Comparison of different studies from 1996 to 2000: (Source: research center Karlsruhe) 10.0 US$ (billions) NEXUS (max.) (1997) NEXUS (min.) (1997) Battelle (1990) SGT (Germany) (1996) Systems Planning Corp. (SPC 1994) SEMI (1995) SRI Consulting (1997) Intelligent Microsensors Technology (1996) Venture Development Corp. (MST) (2000) Venture Development Corp. (MEMS) (2000) SPC (1999) Japan Micromachine Center (max.) (1999) Japan Micromachine Center (min.) (1999) Year Quelle/Source: Forschungszentrum Karlsruhe, Technik und Umwelt, Prozessentwicklung & Versuchstechnik
8 Concept Microsystem
9 Battenfeld MICROSYSTEM 50 concept solution for the micro moulding market complete manufacturing cell designed and optimized for part weights < 1g B4 fully closed loop control closed clean-room production cell all electric servo drives high dynamic process fast cycle optimized mould technology modular design: injection module clamp module rotary table module automatic part handling module*, optical quality control module*, clean-room module*, storage packing module* and various other options *optional Quelle/Source:Battenfeld
10 time line Battenfeld MICROSYSTEM 50 project start March 1997 concept release Dec first study presentation June 1998 K98 3 machines running Oct customer trials Feb revision, Marketing Aug selling release FAKUMA 99 Oct optimization until Jan first sold MICROSYSTEM Feb sold MICROSYSTEMS in more than 20 June 2006 countries worldwide
11 production lines with Microsystem 50 (D, UK) Quelle/Source: Horst Scholz GmbH & Co. KG
12 different approaches to produce micro parts standard technology micro technology slow process large moulds large sprues high energy consumption part free falling quality check afterwards peripheral technology oversized high dynamic process optimized mould technology small sprues efficient energy consumption integrated part handling automatic quality assurance adjust peripheral technology
13 single step system standard technology down scaled technology standard injection mould machines for small pieces manufactor + type Arburg GmbH & Co. KG Allrounder 170 U Battenfeld Kunststoffmaschinen GmbH HM 250 Micromelt Dr. Boy GmbH & Co. KG Boy 12 A Demag Ergotech GmbH IntElect 50 Engel Austria GmbH E-Motion (X-Melt) Krauss-Maffei-Kunststofftechnik GmbH KM CX Mitsui Machine Tool Fanuc Roboshot S-2000i 5A Sumitomo Plastics-Machinery SE18D Toshiba Machine Co. EC20P-0.4 clamping force [kn] injection unit Screw diameter 15 mm Screw diameter 14 mm Screw diameter 12 mm Screw diameter 14 mm Precompression of the melt Screw diameter 18 mm Screw diameter 15 mm Screw diameter 14 mm Screw diameter 14 mm Screw diameter 16 mm Quelle/Source: FZ Karlsruhe
14 single step system standard technology down scaled technology thermal separation of sprue and melt cushion, creates each cycle a cold material slug at on the nozzle tip large melt cushion cold material slug on the nozzle long flow length 1 mg shot weight needs 0,0056 mm stroke on a 14 mm screw difficult to control small shot weight
15 two step system semi micro technology - split plasticizing and injecting screw-piston-machines for microparts manufactor + type Cronoplast, sl bzw. ICH- Christmann Babyplast 6/10 Ettlinger Kunststoffmaschinen GmbH D-I-M Ferromatik Milacron GmbH K-TEC Kunststoff-Zentrum Leipzig GmbH formicaplast M2 Sodick Plustech Co., Ltd. TR05EH clamping force [kn] > injection unit Preplastification 1 Piston 10/12/14/16/18 mm 1 Extruder 16/20 mm 1 Piston 6/8/10 mm 1 Extruder 18 mm 1 Piston 7/9/11 mm Piston-Preplastification 1 Piston 3 mm 1 Extruder 14 mm 1 Piston 12 mm Quelle/Source: FZ Karlsruhe
16 two step system semi micro technology - split plasticizing and injecting thermal separation of sprue and melt cushion, creates each cycle a cold material slug at on the nozzle tip large melt cushion cold material slug on the nozzle injection of thermal inconsistent material long flow length Quelle/Source:Battenfeld
17 three step system micro technology - split plasticizing, dosing and injecting screw piston-machines for precise, small micro parts manufactor + type Battenfeld Kunststoffmaschinen GmbH Microsystem 50 clamping force [kn] 50 injection unit 1 Extruder 14 mm 2 Pistons 5 (3) mm Quelle/Source: FZ Karlsruhe
18 three step system micro technology - split plasticizing, dosing and injecting no material between cold mould and injection unit very small melt cushion no cold material slug injection of thermal homogeneous material very short flow length The Microsystem 50 is the only system which is designed and optimized for part weights below 100 mg
19 comparison melt cushion standard technology micro technology sprue 0,9 cm 3 melt cushion 5,2 cm 3 sprue (melt cushion) 0,13 cm 3 slug 0,15 cm 3 melt cushion + slug + sprue : 6,25 cm 3 melt cushion + sprue : 0,13 cm 3 standard melt cushion ratio = ~ 48 micro 1 Quelle/Source:Battenfeld
20 comparison sprue size standard technology micro technology sprue weight: mg sprue weight: mg standard sprue weight ratio = ~ 20 micro 1
21 sprue dimension of the Microsystem 50 Quelle/Source: Battenfeld
22 comparison injecting process standard and semi micro technology optimization only on machine side disadvantage: - Large melt cushion - Cold material slug on the nozzle - Long flow length micro technology optimization of machine and mould advantage: - very small melt cushion - no cold material slug - very short flow length
23 Injection process
24 development philosophy standard injection molding screw combines all functions in one MICROSYSTEM is splitting the functions for the most ideal solution per function without any compromise plasticizing metering locking injecting
25 injection process mounting plate nozzle pressure sensor piston dosing sleeve extruder screw sprue shut-off valve moulded part injection piston heater mould Machine
26 injection process Quelle/Source:Battenfeld
27 comparison switch - over time Machine type Dimensions Ømm Injection velocity Switch over time till complete stop Decelerationvolume Decelerationstroke Hydraulic machine 14 screw 250 mm/s 40 ms 5,0 mm 770 mm 3 Elektric drive Microsystem 5 plunger 250 mm/s 6 ms 0,75 mm 15 mm 3 Elektric drive Microsystem with forecast pressure contol (closed loop control) 5 plunger 250 mm/s forecast pressure contol system: Control deceleration to target pressure without over shooting target pressure 0 mm 0 mm 3 Quelle:Battenfeld
28 comparison switch - over time Machine type Dimensions Ømm Injection velocity Switch over time till complete stop Decelerationvolume Decelerationstroke Hydraulic machine 14 screw 250 mm/s 40 ms 5,0 mm 770 mm 3 Elektric drive Microsystem 5 plunger 250 mm/s 6 ms 0,75 mm 15 mm 3 Elektric drive Microsystem with forecast pressure contol (closed loop control) 5 plunger 250 mm/s forecast pressure contol system: Control deceleration to target pressure without over shooting target pressure 0 mm 0 mm 3 Velocity injection motor 250mm/s Forecast pressure control system Microsystem Mould pressure Deceleration injection motor Target mould pressure 800 Bar Start for pressure control Cavity fillet End pressure control Cavity start fill 0mm/s 0 Bar time 6 ms = second Quelle:Battenfeld
29 comparison switch - over time Machine type Dimensions Ømm Injection velocity Switch over time till complete stop Decelerationvolume Decelerationstroke Hydraulic machine 14 screw 250 mm/s 40 ms 5,0 mm 770 mm 3 Elektric drive Microsystem with forecast pressure contol (closed loop control) 5 plunger 250 mm/s forecast pressure contol system: Control deceleration to target pressure without over shooting target pressure 0 mm 0 mm Injection speed mm/s Injection volume mm³ Mikrosystem 50 Hydraulic machine Quelle:Battenfeld
30 micromechanical parts part: material: Wall thickness: Housing POM 0.08mm Quelle/Source: Horst Scholz GmbH & Co. KG
31 benefits injection module All standard granulate sizes are possible because of the 14 mm screw Stress free plasticization and dosing in a low pressure area (max. 1.1 cm³) Each shot new dosing wit new raw material and an accuracy of 1 mm 3 Material acceleration to end speed before injection (max. 760 mm/sec.) Shortest runners and gates => process conditions near the cavity Rigid injection system without pumping in the injection process Injection of thermal homogeneous material Deceleration volume of the injection unit approx. 2 mm 3 (at 250 mm/sec.) High processing security and excellent reproducibility results Minimum of pressure lost (max bar) Cycle time dry from 1,5 sec. (standard projects between 2 and 5 sec.) Quelle/Source:Battenfeld
32 Size of injection unit, plasticizing and injection components Quelle/Source:Battenfeld
33 Size of Microsystem plasticization screws: 14 mm PIM screw Microsystem mm MICROMELT 14 mm standard screw Microsystem mm special powder application Microsystem 50 Quelle/Source:Battenfeld
34 Basic Modules
35 Microsystem basic modules injection module Four-level servo-electrical and mechanical combination clamping module clamping force 50 kn positioning precision 0,01 mm rotary table module parallel function of injecting and ejecting Quelle/Source:Battenfeld
36 UNILOG B4 controller strong and flexible screen: large, high-resolution 10,4 color screen operation: universal Windows TM -style user platform for all machine models quality assurance: detailed process documentation and monitoring storage of data: on 3½ floppy disk safety: password system Quelle/Source:Battenfeld
37 Options
38 Microsystem extract from optional modules handling module parts deposit separated cavity by cavity, velocity 2 m/sec. clean-room module until ISO class 100 in the working area storage packing module blister strap with protective foil or trays with automatic changer Quelle/Source:Battenfeld
39 Production with Microsystem Micro-Gear part weight 0,0008 g material POM Quelle/Source: Battenfeld
40 Video-quality control system hardware separate CPU LCD-Touch screen UPS electric supply special I/O-card 1 up to 4 cameras camera high resolution objective (Lens) lighting installation connection with B4 software sherlock 32 IMAGING technology optical high speed-quality control system Quelle/Source:Battenfeld
41 Mould Technology
42 mould technology for micro parts
43 Micro mould for Microsystem 50 2-cavity mould, changeable insert system, Test bar Quelle/Source:Battenfeld
44 Micro mould for Microsystem 50 Quelle/Source:Battenfeld
45 Micro mould for Microsystem 50 Quelle/Source:Battenfeld
46 Materials
47 Injected* materials on the Microsystem 50 STANDARD PP Polypropylene PE Polyethylene PS Polystyrene TECHNICAL POM Polyoxymethylene PA Polyamide ABS Acrylnitrid-Butadiene-Styrene PBT Polybuthyleneterephthalate PPS Polyphenylensulfide LCP Liquid Crystal Polymer PEEK Polyetheretherketone ETFE Ethylene / Tetrafluorethylene OPTICAL PC Polycarbonate PMMA Polymethylmethacrylate COC Cycloolefin Copolymere PSU Polysulfone SAN Styrene-Acrylnitril PETG Polyethylene terephtalate POWDER MIM Metal Injection Molding CIM Ceramic Injection Molding MEDICAL PDLL Bio lactate ELASTOMER TPE Thermoplastic Elastomere TPU Thermoplastic Urethane * Extract Quelle/Source:Battenfeld
48 Applications
49 Micromechanical parts Part: Material: Mold: Part volume: Shot volume: Application: switch Locking lever POM 2-cavity, 3-plate gating 0,00070 cm³ / 0,70 mm³ 0,093 cm³ / 93 mm³ Micromechanical, micro Part: Material: Mold: Part volume: Shot volume: Application: Latch POM +15% GF 2-cavity, 3-plate gating 0,0026 cm³ / 2,6 mm³ 0,100 cm³ / 100 mm³ Watch-industry Part: Material: Mold: Part volume: Shot volume: Application: Catch wheel PA +20% GF 4-cavity, 2-plate gating 0,0053 cm³ / 5,3 mm³ 0,112 cm³ / 112 mm³ Micro switch Quelle/Source: Battenfeld, ETA SA, Horst Scholz GmbH & Co. KG
50 Micro gear wheel Part: Material: Mold: Part volume: Shot volume: Application: Dented wheel POM 4-cavity, 3-plate gating 0,00042 cm³ / 0,42 mm³ 0,136 cm³ / 136 mm³ Watch industry Part: Material: Mold: Part volume: Shot volume: Application: Rotor with gear wheel POM 4-cavity, 3-plate gating 0,0007 cm³ / 0,7 mm³ 0,132 cm³ / 132 mm³ Watch industry Part: Material: Mold: Part volume: Shot volume: Application: Gear wheel POM x-cavity, 3-plate gating 0,040 cm³ / 40,0 mm³ --- cm³ / --- mm³ Micro gear Quelle/Source: Battenfeld, Rolla Micro-Synthetics AG, Horst Scholz GmbH & Co. KG
51 Micro gear wheel Part: Material: Mold: Part volume: Shot volume: Application: Spur wheel PA x-cavity, x-plate gating --- cm³ / --- mm³ --- cm³ / --- mm³ Electrical technology Part: Material: Mold: Part volume: Shot volume: Application: Spiral gear PPT x-cavity, x-plate gating --- cm³ / --- mm³ --- cm³ / --- mm³ Electrical technology/metrology Part: Material: Mold: Part volume: Shot volume: Application: Worm wheel PPT x-cavity, x-plate gating --- cm³ / --- mm³ --- cm³ / --- mm³ Electrical technology/metrology Quelle/Source: Battenfeld, Horst Scholz GmbH & Co. KG
52 Micro filter / medical industry Part: Material: Mold: Part volume: Shot volume: Application: Micro filter 40µm mesh size POM 2-cavity, 3-plate gating 0,00056 cm³ / 0,56 mm³ 0,091 cm³ / 91 mm³ Medical industry, acoustics Part: Micro filter 80µm mesh size Material: POM Mold: 2-cavity, 3-plate gating Part volume: 0,00063 cm³ / 0,63 mm³ Shot volume: 0,092 cm³ / 92 mm³ Application: Medical industry, acoustics Part: Material: Mold: Part volume: Shot volume: Application: Micro filter POM 2-cavity, 3-plate gating 0,0039 cm³ / 3,9 mm³ 0,288 cm³ / 288 mm³ Medical industry, hearing aid Quelle/Source: Battenfeld, Oticon A/S
53 Mould insert for a 40µm filter Quelle/Source: Battenfeld
54 Micro parts for medical industry Part: Material: Mold: Part volume: Shot volume: Application: Implantable clip bio-degradable 1-cavity, 3-plate gating 0,011 cm³ / 11,0 mm³ 0,037 cm³ / 37 mm³ Medical industry Part: Material: Mold: Part volume: Shot volume: Application: Bearing shell / bearing cap PEEK 1+1-cavity, 2-plate gating 0,006 / 0,013 cm³ 6,0 / 13 mm³ --- cm³ / --- mm³ Medical industry Part: Material: Mold: Part volume: Shot volume: Application: Sensor housing implantable POM 2+2-cavity, 3-plate gating 0,0037 cm³ / 3,7 mm³ 0,159 cm³ / 159 mm³ Medical industry, hearing aid Quelle/Source: Battenfeld, Aesculap AG & Co. KG, Horst Scholz GmbH & Co. KG
55 Micro parts for medical industry Part: Material: Mold: Part volume: Shot volume: Application: Impeller PEEK 1-cavity, 3-plate gating --- cm³ / --- mm³ --- cm³ / --- mm³ Medical intercardial pump system Part: Material: Mold: Part volume: Shot volume: Application: vascular clamp bio-resorbable 4-cavity, 3-plate gating 0.005cm³ / 5 mm³ cm³ / 124 mm³ Medical clamp Quelle/Source: Horst Scholz GmbH & Co. KG
56 Micromechanical parts Part: Material: Mold: Part volume: Shot volume: Application: Operating pin LCP 4 and (8)-cavity, 2-plate gating 0,012 cm³ / 12,0 mm³ 0,077 cm³ / 77 mm³ (0,125 cm³ / 125 mm³) Micro switch Part: Material: Mold: Part volume: Shot volume: Application: Gear plate POM x-cavity, x-plate gating --- cm³ / --- mm³ --- cm³ / --- mm³ Motive power engineering Part: Material: Wall thickness: weight : Sleeve PEEK 0.15mm 0.001gr Quelle/Source: Battenfeld, Horst Scholz GmbH & Co.KG
57 Multicolor micro parts / Insert micro parts Part: Material: Mold: Part volume: Shot volume: Application: Part: Material: Mold: Part volume: Shot volume: Application: Coax plug / switch MID LCP / LCP (two-color injection molding) 8-cavity, 2-plate gating 0,051 cm³ / 51 mm³ (0,03 cm³ / 3 mm³) 0,529 cm³ / 529 mm³ (0,141 cm³ / 141 mm³) Mobile phone Plate POM 4-cavity, 3-plate gating --- cm³ / --- mm³ --- cm³ / --- mm³ Lifestyle Part: Material: Mold: Part volume: Shot volume: Application: Aseptic expendable precision blade XXX x-cavity, x-plate gating --- cm³ / --- mm³ --- cm³ / --- mm³ Medical industry Quelle/Source: Battenfeld, Horst Scholz GmbH & Co. KG, Tyco Electronics
58 Micro connectors Part: Material: Mold: Part volume: Shot volume: Application: SIM Card Connector LCP 4-cavity, 3-plate gating 0,072 cm³ / 72,0 mm³ 0,418 cm³ / 418 mm³ Mobile phone Part: Material: Mold: Part volume: Shot volume: Application: 30-pin Connector LCP 4-cavity, 2-plate gating 0,026 cm³ / 26 mm³ 0,155 cm³ / 155 mm³ Mobile phone Part: Material: Mold: Part volume: Shot volume: Application: 28pin-TL2 Micro Subconnector POM 2 -cavity, 2-plate gating 0,003 cm³ / 3 mm³ 0,098 cm³ / 98 mm³ Medical industry, hearing aid Quelle/Source: Battenfeld, MEW
59 Mould inserts for a micro connector
60 Optical micro parts Part: Material: Mold: Part volume: Shot volume: Application: IR - Window PC 4+4 -cavity, 2-plate gating 0,058 / 0,053 cm³ 58 / 53 mm³ 0,735 cm³ / 735 mm³ Mobile phone Quelle/Source: Battenfeld, Perlos Oy
61 Micro structured micro parts Part: Material: Mold: Part volume: Shot volume: Application: Sensor disk structure 0,8µm PC 1-cavity, 3-plate gating 0,153 cm³ / 153 mm³ 0,296 cm³ / 296 mm³ Motive power engineering, sensor technology Quelle/Source: Battenfeld, Horst Scholz GmbH & Co. KG
62 Micro - PIM / MIM + CIM Part: Material: Mold: Part volume: Shot volume: Application: Meander MIM 1-cavity, 2-plate gating 0,010 cm³ / 10 mm³ 0,065 cm³ / 65 mm³ Micromechanics Part: Material: Mold: Part volume: Shot volume: Application: Gear wheel MIM 1-cavity, 3-plate gating --- cm³ / --- mm³ --- cm³ / --- mm³ Micromechanics Part: Material: Mold: Part volume: Shot volume: Application: Test bar MIM 1+ 1-cavity, 2-plate gating 0,00045 / 0,00015 cm³ 0,45 / 0,15 mm³ 0,10265 cm³/ 102,65 mm³ Trials Quelle/Source: Battenfeld, Taisei Kogyo CO.,LTD, Horst Scholz GmbH & Co. KG, FZ Karlsruhe
63 Stirrup material: high-grade steel 316L Source: Frauenhofer IFAM Bremen, Krämer EngineeQuelle/ring
64 SM - Ferrules 125 µm diameter Part: Material: Mold: Part volume: Shot volume: Application: Single fiber, single mode ferrules LCP 1-cavity, 3-plate gating 0,050 cm³ / 50,0 mm³ 0,260 cm³ / 260 mm³ Ferrules Single mode < = 1.0µm, Multi mode tolerance < = 3.0 µm Part: Material: Mold: Part volume: Shot volume: Application: Multi fiber, single mode Ferrules, development projects LCP 1-cavity, 3-plate gating 0,050 cm³ / 50,0 mm³ 0,260 cm³ / 260 mm³ Ferrules Single mode < = 1.0µm, Multi mode tolerance < = 3.0 µm Quelle/Source:Battenfeld, Rapidwerks
65 Micromechanical parts Part: Housing Material: LCP Part weight: g Application : Micro switch Quelle/Source: Horst Scholz GmbH & Co. KG
66 Benefits / Resume
67 The worldwide unique solution for micro precision parts: 1. min. double quality compared to conventional moulding 2. designed and optimized for part weights below 100 mg 3. up to 80% material savings due to sprue and part relation 4. 2/3 of energy savings compared to conventional moulding times faster injection than conventional moulding 6. generally half the cycle time compared to conventional moulding 7. advanced production cell due to optimized mould technology, small footprint, all-in-one solution Quelle/Source:Battenfeld
68 MICROSYSTEM 50 An easy and secure way into the growing market of MST Quelle/Source:Battenfeld
69 Resume Many things that seem obvious now were an impossible dream not too long ago. Part volume: 0,00065 cm³ (Shot volume 0,07 cm³) And many things that seem impossible today might be reality soon.
70 Many thanks for your attention More information under Quelle/Source:Battenfeld
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