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Microsystem
Part volume:
0,00065 cm³(Shot volume 0,07 cm³)
the innovative solution for microprecision partsthe innovative solution for microprecision parts
Micro-MouldingBattenfeld Injection Molding
MicrosystemMicroMicro--MouldingMoulding
the innovative system solution for moulding the innovative system solution for moulding of micro precision partsof micro precision parts
Too small for conventional injection moulding machinesToo small for conventional injection moulding machines
Quelle/Source: Battenfeld, Horst Scholz GmbH & Co .KG
Microsystem
contents
1. Market
2. Concept Microsystem
3. Injection process
4. Basic modules
5. Options
6. Mould technology
7. Materials
8. Applications
9. Benefits / Summary
Microsystem
Market
Microsystem
Why downsizing products?less weight
smaller dimensions
with more functions
less energy consumption
new products
needs high precision
market trend: reduction of part weights < 0.1 g
micro precision parts
Microsystem
Quelle/Source:Battenfeld
which markets need micro parts
Automotive Micro switch, sensors, ABS-SystemsComputer Head of an ink-jet printerTelecommunication Mobile phone, MIDConnectors Plug connectors, opto couplersElectronics Micro parts on circuit boardsMicro-equipment Valve technologyMedical technology Hearing aids, implants, biodegradableSensors Airbag sensors, sensor diskMicromechanics Micro motors, rotorsOptics Lenses, displaysWatches Gear wheels, latches, micro transmissionsGlass fiber conductors Ferrules, connectorsMicrostructure Lab on the Chip, data carrierPrecise suppliers Various partsSpecial materials PIM ( MIM / CIM ), PTFEInstitutes, Universities Material-, technology research
Microsystem
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)
US$
(bill
ions
)
100.0
10.0
1.0
0.1
Year
1990
1992
1994
1996
1998
2000
2012
2010
2008
2002
2014
2004
2006
Comparison of different studies from 1996 to 2000:
(Source: research center Karlsruhe)
Quelle/Source: Forschungszentrum Karlsruhe, Technik und Umwelt, Prozessentwicklung & Versuchstechnik
world market expectations MST
Microsystem
Concept Microsystem
Microsystem
complete manufacturing celldesigned and optimized for part weights < 1gB4 fully closed loop controlclosed clean-room production cellall electric servo driveshigh dynamic processfast cycleoptimized mould technologymodular design:injection moduleclamp module rotary table moduleautomatic part handling module*,optical quality control module*, clean-room module*,storage packing module*and various other options
*optional
Battenfeld MICROSYSTEM 50 concept solution for the micro moulding marketsolution for the micro moulding market
Quelle/Source:Battenfeld
Microsystem
project start March 1997
concept release Dec. 1997
first study presentation June 1998
K98 3 machines running Oct. 1998
customer trials Feb. 1999
revision, Marketing Aug. 1999
selling release FAKUMA 99 Oct. 1999
optimization until Jan. 2000
first sold MICROSYSTEM Feb. 2000
100 sold MICROSYSTEMS in more than 20 June 2006countries worldwide
time line Battenfeld MICROSYSTEM 50
Microsystem
Quelle/Source: Horst Scholz GmbH & Co. KG
production lines with Microsystem 50 (D, UK)
Microsystem
• high dynamic process
optimized mould technology
small sprues
efficient energy consumption
integrated part handling
automatic quality assurance
adjust peripheral technology
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
Microsystem
Screw diameter 16 mm200Toshiba Machine Co.EC20P-0.4
Screw diameter 14 mm180Sumitomo Plastics-MachinerySE18D
Screw diameter 14 mm50Mitsui Machine Tool – FanucRoboshot S-2000i 5A
Screw diameter 15 mm350Krauss-Maffei-Kunststofftechnik
GmbHKM 35-55 CX
Precompression of the meltScrew diameter 18 mm
550Engel Austria GmbHE-Motion (X-Melt)
Screw diameter 14 mm500Demag Ergotech GmbHIntElect 50
Screw diameter 12 mm129Dr. Boy GmbH & Co. KGBoy 12 A
Screw diameter 14 mm250Battenfeld Kunststoffmaschinen
GmbHHM 250 Micromelt
Screw diameter 15 mm123 – 180Arburg GmbH & Co. KGAllrounder 170 U
injection unitclamping force [kN]manufactor + type
single step systemstandard technology – down scaled technologystandard injection mould machines for small pieces
Quelle/Source: FZ Karlsruhe
Microsystemsingle step systemstandard technology – down scaled technology
• 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
thermal separation of sprue and melt cushion, creates each cycle a cold material slug at on the nozzle tip
Microsystem
1 Extruder 14 mm1 Piston 12 mm
49Sodick Plustech Co., Ltd.TR05EH
Piston-Preplastification1 Piston 3 mm
10Kunststoff-Zentrum Leipzig GmbH
formicaPlast M2
1 Extruder 18 mm1 Piston 7/9/11 mm
> 400Ferromatik Milacron GmbHK-TEC
1 Extruder 16/20 mm1 Piston 6/8/10 mm
100Ettlinger Kunststoffmaschinen GmbHD-I-M
Preplastification1 Piston 10/12/14/16/18 mm
62Cronoplast, sl bzw. ICH- ChristmannBabyplast 6/10
injection unitclamping force [kN]
manufactor + type
two step systemsemi micro technology - split plasticizing and injectingscrew-piston-machines for microparts
Quelle/Source: FZ Karlsruhe
Microsystemtwo step systemsemi micro technology - split plasticizing and injecting
Quelle/Source:Battenfeld
• large melt cushion• cold material slug on the nozzle• injection of thermal inconsistent material• long flow length
thermal separation of sprue and melt cushion, creates each cycle a cold material slug at on the nozzle tip
Microsystem
1 Extruder 14 mm2 Pistons 5 (3) mm
50Battenfeld Kunststoffmaschinen GmbHMicrosystem 50
injection unitclamping force [kN]
manufactor + type
three step systemmicro technology - split plasticizing, dosing and injectingscrew–piston-machines for precise, small micro parts
Quelle/Source: FZ Karlsruhe
Microsystemthree step systemmicro technology - split plasticizing, dosing and injecting
• very small melt cushion• no cold material slug• injection of thermal homogeneous material• very short flow length
no material betweencold mould and injection unit
The Microsystem 50 is the only system which is designed and optimized for part weights below 100 mg
Microsystem
sprue (melt cushion) 0,13 cm3
melt cushion + slug + sprue : 6,25 cm3 melt cushion + sprue : 0,13 cm3
comparison melt cushion
Quelle/Source:Battenfeld
standard technology micro technology
sprue 0,9 cm3
melt cushion 5,2 cm3
slug 0,15 cm3
melt cushion ratio = ~ 481
standardmicro
Microsystemcomparison sprue size
standard technology micro technology
sprue weight: 1.000 – 2.500 mg sprue weight: 50 - 200 mg
sprue weight ratio = ~ 201
standardmicro
Microsystemsprue dimension of the Microsystem 50
Quelle/Source: Battenfeld
Microsystem
standard and semi micro technologyoptimization only on machine sidedisadvantage:- Large melt cushion- Cold material slug on the nozzle- Long flow length
micro technologyoptimization of machine and mouldadvantage:- very small melt cushion- no cold material slug- very short flow length
comparison injecting process
Microsystem
Injection process
Microsystemdevelopment philosophy
MICROSYSTEM is splitting the functions for the most ideal solution per function without any compromise
standard injection molding screw combines all functions in one
plasticizing metering locking injecting
Microsystem
Machinemould
sprue
nozzlemounting plate
heater
injection piston
shut-off valve
extruder screw
moulded part
dosing sleevepressure sensor piston
injection process
Microsystem
Quelle/Source:Battenfeld
Microsysteminjection process
Microsystem
Quelle:Battenfeld
0 mm30 mmforecast pressure contol system:Control deceleration to target pressurewithout over shooting target pressure
250 mm/s5 plungerElektric drive Microsystemwith forecast pressure contol(closed loop control)
15 mm30,75 mm6 ms250 mm/s5 plungerElektric drive Microsystem
770 mm35,0 mm40 ms250 mm/s14 screwHydraulic machine
Deceleration-volume
Deceleration-stroke
Switch –over time tillcomplete stop
Injectionvelocity
DimensionsØ mm
Machine type
comparison switch - over time
Microsystem
Quelle:Battenfeld
6 ms
Velocity injection motor
time0mm/s
250mm/s
Start forpressure control
Target mould pressure
Decelerationinjection motor
Forecast pressure control system Microsystem
Cavity fillet
0 Bar
800 Bar
Endpressure control
Cavity start fill
Mould pressure
= 0.006 second
0 mm30 mmforecast pressure contol system:Control deceleration to target pressurewithout over shooting target pressure
250 mm/s5 plungerElektric drive Microsystemwith forecast pressure contol(closed loop control)
15 mm30,75 mm6 ms250 mm/s5 plungerElektric drive Microsystem
770 mm35,0 mm40 ms250 mm/s14 screwHydraulic machine
Deceleration-volume
Deceleration-stroke
Switch –over time tillcomplete stop
Injectionvelocity
DimensionsØ mm
Machine type
comparison switch - over time
Microsystem
Quelle:Battenfeld
0
100
200
300
400
500
600
700
800
0 200 400 600 800 1000 1200 1400 1600Injection volume mm³
Inje
ctio
nsp
eed
mm
/s
Mikrosystem 50
Hydraulic machine
0 mm30 mmforecast pressure contol system:Control deceleration to target pressurewithout over shooting target pressure
250 mm/s5 plungerElektric drive Microsystemwith forecast pressure contol(closed loop control)
770 mm35,0 mm40 ms250 mm/s14 screwHydraulic machine
Deceleration-volume
Deceleration-stroke
Switch –over time tillcomplete stop
Injectionvelocity
DimensionsØ mm
Machine type
comparison switch - over time
Microsystem
Quelle/Source: Horst Scholz GmbH & Co. KG
micromechanical parts
part: Housingmaterial: POMWall thickness: 0.08mm
Microsystem
All standard granulate sizes are possible because of the 14 mm screwStress 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 mm3
Material acceleration to end speed before injection (max. 760 mm/sec.)Shortest runners and gates => process conditions near the cavityRigid injection system without „pumping“ in the injection processInjection of thermal homogeneous materialDeceleration volume of the injection unit approx. 2 mm3 (at 250 mm/sec.)High processing security and excellent reproducibility resultsMinimum of pressure lost (max. 2500 bar)Cycle time dry from 1,5 sec. (standard projects between 2 and 5 sec.)
benefits injection module
Quelle/Source:Battenfeld
MicrosystemSize of injection unit, plasticizing and injection components
Quelle/Source:Battenfeld
MicrosystemSize of Microsystem plasticization screws:
14 mm PIM screw Microsystem 5014 mm MICROMELT14 mm standard screw Microsystem 5012 mm special powder application Microsystem 50
Quelle/Source:Battenfeld
Microsystem
Basic Modules
Microsystem
clamping moduleclamping force 50 kNpositioning precision 0,01 mm
rotary table moduleparallel function of injecting and ejecting
injection moduleFour-level servo-electrical and mechanical combination
Microsystem basic modules
Quelle/Source:Battenfeld
Microsystem
screen:large, high-resolution 10,4“ color screen
operation:universal WindowsTM -style user platform for all machine models
quality assurance:detailed process documentation and monitoring
storage of data:on 3½“ floppy disk
safety: password system
UNILOG B4 controller – strong and flexible
Quelle/Source:Battenfeld
Microsystem
Options
Microsystem
clean-room moduleuntil ISO class 100 in the working area
storage packing moduleblister strap with protective foil or trays with automatic changer
handling moduleparts deposit separated cavity by cavity, velocity 2 m/sec.
Microsystem extract from optional modules
Quelle/Source:Battenfeld
MicrosystemProduction with Microsystem
Micro-Gear part weight 0,0008 g material POM
Quelle/Source: Battenfeld
Microsystem
hardwareseparate CPULCD-Touch screenUPS electric supplyspecial I/O-card
1 up to 4 camerascamera high resolutionobjective (Lens)lightinginstallationconnection with B4
softwaresherlock 32IMAGING technologyoptical high speed-quality control system
Video-quality control system
Quelle/Source:Battenfeld
Microsystem
Mould Technology
Microsystemmould technology for micro parts
Microsystem
2-cavity mould, changeable insert system, Test bar
Quelle/Source:Battenfeld
Micro mould for Microsystem 50
MicrosystemMicro mould for Microsystem 50
Quelle/Source:Battenfeld
MicrosystemMicro mould for Microsystem 50
Quelle/Source:Battenfeld
Microsystem
Materials
Microsystem
STANDARDPP PolypropylenePE PolyethylenePS Polystyrene
TECHNICALPOM PolyoxymethylenePA PolyamideABS Acrylnitrid-Butadiene-StyrenePBT PolybuthyleneterephthalatePPS PolyphenylensulfideLCP Liquid Crystal PolymerPEEK PolyetheretherketoneETFE Ethylene / Tetrafluorethylene
ELASTOMERTPE Thermoplastic ElastomereTPU Thermoplastic Urethane
OPTICALPC PolycarbonatePMMA PolymethylmethacrylateCOC Cycloolefin CopolymerePSU PolysulfoneSAN Styrene-AcrylnitrilPETG Polyethylene terephtalate
POWDERMIM Metal Injection MoldingCIM Ceramic Injection Molding
MEDICALPDLL Bio lactate
* Extract
Injected* materials on the Microsystem 50
Quelle/Source:Battenfeld
Microsystem
Applications
Microsystem
Quelle/Source: Battenfeld, ETA SA, Horst Scholz GmbH & Co. KG
Part: Locking leverMaterial: POMMold: 2-cavity, 3-plate gatingPart volume: 0,00070 cm³ / 0,70 mm³Shot volume: 0,093 cm³ / 93 mm³Application: Micromechanical, micro switch
Part: LatchMaterial: POM +15% GFMold: 2-cavity, 3-plate gatingPart volume: 0,0026 cm³ / 2,6 mm³Shot volume: 0,100 cm³ / 100 mm³Application: Watch-industry
Part: Catch wheelMaterial: PA +20% GFMold: 4-cavity, 2-plate gatingPart volume: 0,0053 cm³ / 5,3 mm³Shot volume: 0,112 cm³ / 112 mm³Application: Micro switch
Micromechanical parts
Microsystem
Quelle/Source: Battenfeld, Rolla Micro-Synthetics AG, Horst Scholz GmbH & Co. KG
Part: Dented wheelMaterial: POMMold: 4-cavity, 3-plate gatingPart volume: 0,00042 cm³ / 0,42 mm³Shot volume: 0,136 cm³ / 136 mm³Application: Watch industry
Part: Rotor with gear wheelMaterial: POMMold: 4-cavity, 3-plate gatingPart volume: 0,0007 cm³ / 0,7 mm³Shot volume: 0,132 cm³ / 132 mm³Application: Watch industry
Part: Gear wheelMaterial: POMMold: x-cavity, 3-plate gatingPart volume: 0,040 cm³ / 40,0 mm³Shot volume: --- cm³ / --- mm³Application: Micro gear
Micro gear wheel
Microsystem
Quelle/Source: Battenfeld, Horst Scholz GmbH & Co. KG
Part: Spur wheelMaterial: PAMold: x-cavity, x-plate gatingPart volume: --- cm³ / --- mm³Shot volume: --- cm³ / --- mm³Application: Electrical technology
Part: Spiral gearMaterial: PPTMold: x-cavity, x-plate gatingPart volume: --- cm³ / --- mm³Shot volume: --- cm³ / --- mm³Application: Electrical
technology/metrology
Part: Worm wheelMaterial: PPTMold: x-cavity, x-plate gatingPart volume: --- cm³ / --- mm³Shot volume: --- cm³ / --- mm³Application: Electrical
technology/metrology
Micro gear wheel
Microsystem
Quelle/Source: Battenfeld, Oticon A/S
Part: Micro filter 40µm mesh sizeMaterial: POMMold: 2-cavity, 3-plate gatingPart volume: 0,00056 cm³ / 0,56 mm³Shot volume: 0,091 cm³ / 91 mm³Application: Medical industry,
acoustics
Part: Micro filter 80µm mesh size
Material: POMMold: 2-cavity, 3-plate gatingPart volume: 0,00063 cm³ / 0,63 mm³Shot volume: 0,092 cm³ / 92 mm³Application: Medical industry,
acoustics
Part: Micro filterMaterial: POMMold: 2-cavity, 3-plate gatingPart volume: 0,0039 cm³ / 3,9 mm³Shot volume: 0,288 cm³ / 288 mm³Application: Medical industry, hearing aid
Micro filter / medical industry
MicrosystemMould insert for a 40µm filter
Quelle/Source: Battenfeld
Microsystem
Quelle/Source: Battenfeld, Aesculap AG & Co. KG, Horst Scholz GmbH & Co. KG
Part: Implantable clipMaterial: bio-degradableMold: 1-cavity, 3-plate gatingPart volume: 0,011 cm³ / 11,0 mm³Shot volume: 0,037 cm³ / 37 mm³Application: Medical industry
Part: Bearing shell / bearing cap
Material: PEEKMold: 1+1-cavity, 2-plate gatingPart volume: 0,006 / 0,013 cm³
6,0 / 13 mm³Shot volume: --- cm³ / --- mm³Application: Medical industry
Part: Sensor housing implantableMaterial: POMMold: 2+2-cavity, 3-plate gatingPart volume: 0,0037 cm³ / 3,7 mm³Shot volume: 0,159 cm³ / 159 mm³Application: Medical industry, hearing aid
Micro parts for medical industry
Microsystem
Quelle/Source: Horst Scholz GmbH & Co. KG
Part: ImpellerMaterial: PEEKMold: 1-cavity, 3-plate gatingPart volume: --- cm³ / --- mm³Shot volume: --- cm³ / --- mm³Application: Medical
intercardial pump system
Micro parts for medical industry
Part: vascular clampMaterial: bio-resorbableMold: 4-cavity, 3-plate gatingPart volume: 0.005cm³ / 5 mm³Shot volume: 0.124 cm³ / 124 mm³Application: Medical clamp
Microsystem
Quelle/Source: Battenfeld, Horst Scholz GmbH & Co .KG
Part: Operating pinMaterial: LCPMold: 4 and (8)-cavity, 2-plate
gatingPart volume: 0,012 cm³ / 12,0 mm³Shot volume: 0,077 cm³ / 77 mm³
(0,125 cm³ / 125 mm³)Application: Micro switch
Part: Gear plateMaterial: POMMold: x-cavity, x-plate gatingPart volume: --- cm³ / --- mm³Shot volume: --- cm³ / --- mm³Application: Motive power engineering
Micromechanical parts
Part: SleeveMaterial: PEEKWall thickness: 0.15mmweight : 0.001gr
Microsystem
Quelle/Source: Battenfeld, Horst Scholz GmbH & Co. KG, Tyco Electronics
Part: PlateMaterial: POMMold: 4-cavity, 3-plate gatingPart volume: --- cm³ / --- mm³Shot volume: --- cm³ / --- mm³Application: Lifestyle
Part: Coax plug / switch MIDMaterial: LCP / LCP (two-color
injection molding)Mold: 8-cavity, 2-plate gatingPart volume: 0,051 cm³ / 51 mm³
(0,03 cm³ / 3 mm³)Shot volume: 0,529 cm³ / 529 mm³
(0,141 cm³ / 141 mm³)Application: Mobile phone
Part: Aseptic expendable precision blade
Material: XXXMold: x-cavity, x-plate gatingPart volume: --- cm³ / --- mm³Shot volume: --- cm³ / --- mm³Application: Medical industry
Multicolor micro parts / Insert micro parts
Microsystem
Quelle/Source: Battenfeld, MEW
Part: SIM Card Connector Material: LCPMold: 4-cavity, 3-plate gatingPart volume: 0,072 cm³ / 72,0 mm³Shot volume: 0,418 cm³ / 418 mm³Application: Mobile phone
Part: 30-pin ConnectorMaterial: LCPMold: 4-cavity, 2-plate gatingPart volume: 0,026 cm³ / 26 mm³Shot volume: 0,155 cm³ / 155 mm³Application: Mobile phone
Part: 28pin-TL2 Micro Sub-connector
Material: POMMold: 2 -cavity, 2-plate gatingPart volume: 0,003 cm³ / 3 mm³Shot volume: 0,098 cm³ / 98 mm³Application: Medical industry, hearing aid
Micro connectors
MicrosystemMould inserts for a micro connector
Microsystem
Quelle/Source: Battenfeld, Perlos Oy
Part: IR - WindowMaterial: PCMold: 4+4 -cavity, 2-plate gatingPart volume: 0,058 / 0,053 cm³
58 / 53 mm³Shot volume: 0,735 cm³ / 735 mm³Application: Mobile phone
Optical micro parts
Microsystem
Quelle/Source: Battenfeld, Horst Scholz GmbH & Co. KG
Part: Sensor disk structure 0,8µmMaterial: PCMold: 1-cavity, 3-plate gatingPart volume: 0,153 cm³ / 153 mm³Shot volume: 0,296 cm³ / 296 mm³Application: Motive power
engineering, sensor technology
Micro structured micro parts
Microsystem
Quelle/Source: Battenfeld, Taisei Kogyo CO.,LTD, Horst Scholz GmbH & Co. KG, FZ Karlsruhe
Part: MeanderMaterial: MIMMold: 1-cavity, 2-plate gatingPart volume: 0,010 cm³ / 10 mm³Shot volume: 0,065 cm³ / 65 mm³Application: Micromechanics
Part: Test barMaterial: MIMMold: 1+ 1-cavity, 2-plate gatingPart volume: 0,00045 / 0,00015 cm³
0,45 / 0,15 mm³Shot volume: 0,10265 cm³/ 102,65 mm³Application: Trials
Part: Gear wheelMaterial: MIMMold: 1-cavity, 3-plate gatingPart volume: --- cm³ / --- mm³Shot volume: --- cm³ / --- mm³Application: Micromechanics
Micro - PIM / MIM + CIM
MicrosystemStirrup material: high-grade steel 316L
Source: Frauenhofer IFAM Bremen, Krämer EngineeQuelle/ring
Microsystem
Quelle/Source:Battenfeld, Rapidwerks
Part: Single fiber, single mode ferrules
Material: LCPMold: 1-cavity, 3-plate gatingPart volume: 0,050 cm³ / 50,0 mm³Shot volume: 0,260 cm³ / 260 mm³Application: Ferrules
Single mode < = 1.0µm, Multi mode tolerance< = 3.0 µm
Part: Multi fiber, single mode Ferrules, development projects
Material: LCPMold: 1-cavity, 3-plate gatingPart volume: 0,050 cm³ / 50,0 mm³Shot volume: 0,260 cm³ / 260 mm³Application: Ferrules
Single mode < = 1.0µm, Multi mode tolerance< = 3.0 µm
SM - Ferrules 125 µm diameter
Microsystem
Quelle/Source: Horst Scholz GmbH & Co. KG
Micromechanical parts
Part: HousingMaterial: LCPPart weight: 0.0022gApplication : Micro switch
Microsystem
Benefits / Resume
Microsystem
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
5. 350 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
The worldwide unique solution for micro precision parts:
Microsystem
An easy and secure way into the growing market of MSTAn easy and secure way into the growing market of MST
MICROSYSTEM 50
Quelle/Source:Battenfeld
Microsystem
Many things that seem obvious now
were an impossible dream not too long ago.
And many things that seem impossible today
might be reality soon.
Part volume:
0,00065 cm³(Shot volume 0,07 cm³)
Resume
Microsystem
Quelle/Source:Battenfeld
Many thanks for your attention
More information under www.battenfeld-imt.com