SEMINAR: Design Challenges for Manufacturing with Powder-Polymer Mixtures

Dr. Kunal Kate, Postdoctoral Associate, Department of Mechanical Engineering, University of Louisville
When Feb 09, 2016
from 11:00 AM to 12:00 PM
Where Sackett Hall, Room 200
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Ceramic injection molding (CIM) is a high volume, shaping process used to manufacture 3D ceramic parts with complex features and shapes. In CIM design it is important to understand the molding behavior as a function of powder-polymer mixture (feedstock) composition in order to achieve desired part dimensions and properties, at high production rates. To improve lead times in product development, CIM design simulations can be performed. However, they require the measurement of physical, thermal and rheological feedstock properties and the availability of such data is limited. Currently there is no reliable design approach available to perform mold-filling simulations for compositions that differ from those with measured feedstock properties. The present seminar presents the findings from a new method to estimate feedstock properties critical to performing CIM simulations. The method identifies powder-polymer mixing models that can estimate feedstock properties for a variety of ceramic systems, evaluates the use of estimated feedstock properties to perform simulations and examines the merits of CIM simulations to predict mold-filling behavior by conducting injection-molding experiments for an aluminum nitride feedstock. The findings from this study will be applied to new directions in additive manufacturing research as well as in teaching materials and process design for manufacturing courses.

Speaker's Biography

Dr. Kunal Kate is a postdoctoral associate in the Materials Innovation Guild at the University of Louisville where he is leading the material property based design and digital process development program for powder injection molding and additive manufacturing. He has earned degrees M.S. and Ph.D. degrees in materials science from Oregon State University and has a B.S. in chemical engineering from Pune University. Dr. Kate has 5+ years experience in design-to-manufacturing and has authored 12 peer-reviewed journal publications. Dr. Kate’s current research is on developing and testing digital tools for metal injection molding and materials development for additive manufacturing of metal and ceramics. He is a recipient of the prestigious Laurels scholarship for 2015 at Oregon State University (OSU) and runner-up at OSU Engineering Expo 2015. Kunal has also been involved with a startup company in materials and product development of biodegradable polymer composites.