Mixing and preparation of highly filled feedstock for ceramic injection molding

Complex net shape ceramic parts may be produced via Ceramic Injection Molding (CIM). Part reliability limits the use of ceramics as an engineering material and is ultimately a function of flaws in the part. Poor homogeneity and dispersion of the ceramic powder in the feedstock contributes to flaws. Feedstock preparation typically involves mixing the ceramic powder into an organic binder via batch mixers and twin-screw extruders. Differing degrees of pre-mixing of components were explored from pre-blending in batch mixers to individual ingredients metered to a twin-screw extruder. Results show that pre mixing in a batch mixer is unnecessary and direct compounding on a twin-screw extruder simplifies the feedstock preparation process.