Investigations for the Optimization of Metal Freeforming using the ARBURG freeformer

The ARBURG freeformer represents an additive manufacturing system for producing thermoplastic components using commercially available polymer granulate. This fabrication process offers the potential to use feedstocks known from the metal injection molding (MIM) sector to manufacture so-called green parts. These parts consist of 60 Vol.-% stainless steel powder and 40 Vol-% organic polymer binding system. By debinding and sintering these green parts, it is possible to economically produce full metal components with mechanical properties comparable to metal injection molding. In this publication, the process of producing stainless steel parts with ARBURG plastic freeforming will be presented. The mechanical properties and part density are optimized by varying manufacturing parameters and raw materials. Furthermore, concepts to optimize and increase the service life of the nozzle are shown and discussed. An increase of at least 250% could be achieved by plasma nitriding and coating components of the discharge system.