It is known that powder characteristics including particle size and distribution, particle shape, and chemical composition are important parameters which influence direct laser sintering of metal powders. In this paper, we introduce a first order kinetics model for densification of steel powders during laser sintering. A densification coefficient (K) is defined which express the potential of different powders to be laser-sintered to a high density dependent on their particle characteristics.

The global metal injection moulding industry is getting mature. The technology is on its way to grow from a niche technology to a widely accepted manufacturing process. This paper addresses the latest technological trends in MIM. Challenges in materials development as well as the current limits of the technology are discussed. Trends in processing like 2-component injection moulding and micro injection moulding are presented. The European MIM market situation is described and some key factors for business success are addressed. In the discussion of future business opportunities best practice examples are included.

There is an increasing demand for PM-processes with the capability to produce parts of higher complexity than with conventional press and sinter technology in high production numbers. Warm-flow-compaction (WFC) makes use of improved flowability of powders when blended in an appropriate ratio with fine powder fractions and lubricating binders. Here the process is shown with examples of PM-Steels. General features possible with the process like pressing of undercuts and threaded bores are shown.

The development of Micro MIM as a new manufacturing process for metallic micro parts made of advanced functional materials has been the subject of considerable research over the last years. This paper addresses important quality aspects on processing of new materials by Micro-MIM. Three examples of new functional materials that can be processed are reviewed in this paper. The first example is two-component-Micro-MIM to obtain multi-functional devices. A micro positioning encoder consisting of a magnetic / non-magnetic material combination is presented. The second issue is series production of the replicate of the smallest human bone in the ear (stapes) from Titanium as an example of medical application. Quality assurance and reproducibility in terms of injection moulding parameters are addressed. In the third part, first results on the processing of the shape memory alloy NiTi by Micro-MIM are presented. Potential applications include biocompatible devices and transportation, for example automotive and aerospace. Processing routes and initial microstructures obtained are discussed.