SBIR-STTR Award

This program proposes to replace petroleum-based chemicals with formulations that are less expensive and safer to use in the environment. Critical to this goal is the incorporation of biopolymer additives require as binders for powder injection molding. Water soluble, cellulose-based polymers that have been processed from wood and cotton are also useful as binders in various ceramic manufacturing processes. In this proposal, we plan to use corn-based polymers that do not require mixing with petroleum distillates. We propose to investigate injection molding processing of electronic packaging material blends of aluminum and magnesium aluminum-silicate using biopolymer formulations of corn starch.

There are three major obstacles in the proposed Phase II program. 1) A Phase II program will apply ultrasonic nondestructive evaluation (NDE) sensor technology to metal injection molding of parts. This program will explore amplitude of through transmission. 2) Phase II will examine the constitutive behavior of the corn-based binders and powder mixtures. This task will build on the working binder combinations developed in Phase I. the corn-based materials can be further chemically modified by adding tertiary or quaternary amino functional groups to carry positive charges. It is anticipated that the quality of these components can be significantly improved for a range of materials manufactured by powder injection molding. If successful this program approach would provide a processing technology that can be transferred to suppliers of many components wishing to use a cheaper and more environmentally friendly binder processing technique. 3) Phase II will involve a Design of Experiments approach to the experimental evaluation of the variables to mature the working concept. This program will bring MIM towards the Army's goal of production of consistent high quality parts and components which are difficult to produce or machine. It is 8VA's objective to deliver prototype components which demonstrate how this process could be used for both military and commercial components. It is anticipated that the applications of the biopolymer materials used in powder injection molding will be determined economically viable in real world manufacturing situations. This research will greatly enhance our ability to provide a low cost and environmentally friendly binder. The NDE processes will also translate into improved component quality at significant savings for the Army and Industry as well.