Fabrication of Micro-Punch Array by Plasma Printing for Micro-Embossing into Copper Substrates

Shiratori, Tomomi; Aizawa, Tatsuhiko; Saito, Yasuo; Dohda, Kuniaki

doi:10.3390/ma12162640

Cited by 3 publications

(1 citation statement)

References 9 publications

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“…The paper on the fabrication of a micro-punch array by plasma printing for micro-embossing into copper substrates was prepared by Shiratori et al [ 41 ]. Copper substrates were wrought to have micro-grooves for packaging by micro-stamping with the use of an AISI316 stainless steel micro-punch array.…”

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Recent Development in Micromanufacturing of Metallic Materials

et al. 2020

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Product miniaturization is a trend for facilitating product usage, enabling product functions to be implemented in microscale geometries, and aimed at reducing product weight, volume, cost and pollution. Driven by ongoing miniaturization in diverse areas including medical devices, precision equipment, communication devices, micro-electromechanical systems (MEMS) and microsystems technology (MST), the demands for micro metallic products have increased tremendously. Such a trend requires development of advanced micromanufacturing technology of metallic materials for producing high-quality micro metallic products that possess excellent dimensional tolerances, required mechanical properties and improved surface quality. Micromanufacturing differs from conventional manufacturing technology in terms of materials, processes, tools, and machines and equipment, due to the miniaturization nature of the whole micromanufacturing system, which challenges the rapid development of micromanufacturing technology. Against such a background, the Special Issue “Micromanufacturing of Metallic Materials” was proposed to present the recent developments of micromanufacturing technologies of metallic materials. The papers collected in the Special Issue include research articles, literature review and technical notes, which have been highlighted in this editorial.

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Recent Development in Micromanufacturing of Metallic Materials

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Manufacturing of Aluminum Alloy Parts from Recycled Feedstock by PIG Die-Casting and Hot Stamping

Aizawa

Kurihara²,

Sakayori³

2022

Lubricants

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PIG (Pin-Injection-Gate) die-casting and hot stamping was developed for fabrication of small-sized and thin-walled aluminum alloy parts from the recycled feedstock. The pure aluminum and aluminum alloy granules were utilized as a feedstock model of recycled materials. The measured mass of granules with the estimated weight from 3D-CAD (Computer Aided Design) of products was poured into the PIG-nozzles before injection. After quickly melting by induction heating inside the PIG-nozzle units, the aluminum melts were injected into a die cavity through the PIG-nozzle. No furnaces and no crucibles were needed to store the melt aluminum stock in different from the conventional die-casting system. No clamping mechanism with huge loading machine was also needed to significantly reduce the energy consumption in casting. Much less wastes were yielded in these processes; the ratio of product to waste, or, the materials efficiency was nearly 100%. Nitrogen supersaturation and TiAlN coating were used to protect the PIG-nozzle and the stamping die surfaces from severe adhesion from aluminum melt. The pure aluminum gears and thin-walled mobile phone case were fabricated by this process. X-ray tomography proved that both products had no cavities, pores and shrinkages in their inside. Using the hot stamping unit, the micro-pillared pure aluminum heatsink was fabricated to investigate the holding temperature effect on the aspect ratio of micro-pillar height to width.

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Plasma Nitriding-Assisted 3D Printing for Die Technology in Digital Micro-Manufacturing

Aizawa¹,

Shiratori²,

Suzuki³

2023

Advances in 3D Printing

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A plasma nitriding-assisted 3D printing method was developed to build up the micro-punch and micro-die systems. Two dimensional punch head and core-die cavity geometries were ink-jet printed or screen-printed onto the AISI316 and SKD11 tool substrate surfaces in following their two-dimensional computer-aided design (CAD) data. The low-temperature plasma nitriding process was utilized to make nitrogen supersaturation only into the unprinted substrates. The sand-blasting and chemical etching were utilized to mechanically or chemically remove the printed parts from punch and die substrate. As sand-blasted and chemically etched AISI316 and SKD11 punches and core-dies were simply finished and used as a die set for micro-embossing, micro-piercing and micro-punching processes. In particular, a micro-pump was selected as a miniature mechanical element. Its 3D CAD geometry was sliced to 2D CAD data for each functional AISI304 stainless steel sheet. A pair of punch and die for each 2D CAD geometry for constituent sheet was prepared by the plasma nitriding-assisted 3D printing. Each sheet was punched out by using this set of punch and die to functionalize each sheet unit in correspondence to the sliced CAD data. These constituent sheets were assembled and joined to a structural unit of micro-pump.

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Fabrication of Micro-Punch Array by Plasma Printing for Micro-Embossing into Copper Substrates

Cited by 3 publications

References 9 publications

Recent Development in Micromanufacturing of Metallic Materials

Recent Development in Micromanufacturing of Metallic Materials

Manufacturing of Aluminum Alloy Parts from Recycled Feedstock by PIG Die-Casting and Hot Stamping

Plasma Nitriding-Assisted 3D Printing for Die Technology in Digital Micro-Manufacturing

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