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Rob Linke, MIMforms LLC - Slide 1 Metal Injection Molded Photonic Device Packaging Rob Linke MIMforms LLC.

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Presentation on theme: "Rob Linke, MIMforms LLC - Slide 1 Metal Injection Molded Photonic Device Packaging Rob Linke MIMforms LLC."— Presentation transcript:

1 Rob Linke, MIMforms LLC - Slide 1 Metal Injection Molded Photonic Device Packaging Rob Linke MIMforms LLC

2 Rob Linke, MIMforms LLC - Slide 2 Outline 1.Metal injection molding defined 2.Manufacturing process 3.Materials for photonics packaging 4.Benefits of metal injection molding 5.Future directions 6.Conclusions and resources

3 Rob Linke, MIMforms LLC - Slide 3 What is MIM?

4 Rob Linke, MIMforms LLC - Slide 4 Metal Injection Molding Utilizes wealth of technology developed for plastic injection molding Injection molding of metal powder compounded with binder (plastic/wax) Debinding of component (solvent or thermal) Sintering of part to final density

5 Rob Linke, MIMforms LLC - Slide 5 Manufacturing Process Design of Component Tooling of Mold Injection Molding Debinding Sintering Optional CNC Machining Finishing/Plating

6 Rob Linke, MIMforms LLC - Slide 6 Compounding Components Metal powder Wax Polymers Goals Sufficient binder to fill all voids Uniform mixture Metal powder at 100x D 50 : 2-10 µm

7 Rob Linke, MIMforms LLC - Slide 7 Injection Molding Virtually identical to plastic injection molding Feedstock is molded at low temperatures (150 o C) with consistency of toothpaste Consists of metal powder in binder matrix (~ 40% binder by volume) Yields green part

8 Rob Linke, MIMforms LLC - Slide 8 Debinding Binder removal from matrix (disposable component) Solvent – water or other solvent Thermal decomposition Results in structurally weak component with small amount of binder remaining

9 Rob Linke, MIMforms LLC - Slide 9 Sintering Sintering densification increases the atomic bonds between particles Temperature is near melting point Density of up to 98.5% Real world example – ice cubes sticking together in freezer Sintering Furnace

10 Rob Linke, MIMforms LLC - Slide 10 Shrinkage in Sintering Green part typically shrinks 15% during sintering Density increases Strength increases Final mechanical properties attained

11 Rob Linke, MIMforms LLC - Slide 11 Post-Sintering Structure 3000x Magnification

12 Rob Linke, MIMforms LLC - Slide 12 CNC Machining and Plating MIM tolerances +/- 0.5% For features <4.0 mm it is +/ mm CNC tolerances +/- 15 µm Plating Gold Nickel Other

13 Rob Linke, MIMforms LLC - Slide 13 MIM Materials: Kovar ® Photonic and optoelectronics packages which match CTE of borosilicate glass 29% W, 17% Co, 53% Fe Properties CTE ( o C) ppm/ o C Density – 7.95 g/cm 3 % Density – 97%

14 Rob Linke, MIMforms LLC - Slide 14 MIM Materials: Iron-Nickel Photonic and optoelectronics packages 50% Fe, 50% Ni Properties CTE – 8.8 ppm/ o C Density – 7.75 g/cm 3 % Density - 95%

15 Rob Linke, MIMforms LLC - Slide 15 MIM Materials: Tungsten-Copper Heatsinks for photonic housings which mirror CTE of borosilicate glass 80%W, 20% Cu as Example Properties CTE – 7.4 ppm/ o C at 50 o C Themal Conductivity – 189 W/m K Density – g/cm 3 % Density - 95%

16 Rob Linke, MIMforms LLC - Slide 16 Infiltrated Tungsten skeleton with liquid Copper Vacuum Sintered Tungsten-Copper powder Tungsten Copper Structures

17 Rob Linke, MIMforms LLC - Slide 17 Why use MIM? Reduce or eliminate individual CNC machining Reduce material waste Enable mass production of intricate, highly detailed structures Reduce total cost Kovar Lens Holder

18 Rob Linke, MIMforms LLC - Slide 18 Machine Once or Many? CNC machining Each part is machined to final shape individually MIM The mold is machined once and parts are molded to final shape production volume package cost CNC MIM

19 Rob Linke, MIMforms LLC - Slide 19 Shape Complexity CNC machining Each detail adds to cost (and time) MIM Details are machined into the mold – once Reproduced in each package during molding shape complexity package cost CNC MIM

20 Rob Linke, MIMforms LLC - Slide 20 Material Waste Reduction CNC removes large amounts of metal to yield housing MIM uses only metal necessary 75% waste reduction typical Runners, gates can be recycled on-site Material waste with CNC Machining

21 Rob Linke, MIMforms LLC - Slide 21 Future Directions Complex designs specifically for MIM manufacturing Custom MIM alloys/mixtures Higher dimensional tolerance MIM components Increasing adoption of MIM package use in North America

22 Rob Linke, MIMforms LLC - Slide 22 Conclusions MIM can be an enabling technology for photonic and optoelectronic packaging Mass production Low/no cost structures Reduced material waste Designs not possible or economical with CNC machining Greater alloy flexibility through batch compounding

23 Rob Linke, MIMforms LLC - Slide 23 Additional Information on MIM Organization: CISP-Center for Innovative Sintered Products-Penn State Book: Injection Molding of Metals and Ceramics German & Bose


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