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Ceramic Injection Molding

At Wunder-Mold, we use only high-quality powders and organic constituents in our injection molding feedstocks. This is to ensure that the components made for our customers are of high quality and are consistently reproducible in order to provide the finest parts at the very best price.
The process involves Alumina powder, which is mixed with an organic binder to form a “feedstock.” This material is then INJECTION MOLDED into a custom-made injection molding tool that has been specially designed utilizing the customer’s specifications. The part that comes from the tool is then DE-BOUND AND SINTERED to form a fully dense part. POST SINTERING PROCESSES are used when the tight manufacturing control of WunderMold’s process is required to provide exacting finished dimensions in the range of +/- two tenths of one thousandth of an inch. All along, the manufactured components are constantly inspected with world-class methods and measuring equipment to insure that the part meets our customer’s exacting requirements.

Tool Design and Manufacture

Wunder-Mold’s engineers and product managers work closely with the customer to design a component that is easily molded and provides the best value. Then, using world-class manufacturing methods, this part design, combined with Wunder-Mold’s design expertise and experience, transforms the customer’s vision into a high quality injection molding tool that will produce the required part.

Injection Molding

Using specially designed closed-loop injection molding machines, Wunder-Mold’s engineers design the injection molding cycle to produce the best possible part at the most advantageous price.

De-binding/Sintering

The non-ceramic components of the molded part are removed in a carefully controlled atmosphere. The part with no binder is then consolidated to a fully dense part during the sintering process, using high temperatures (in excess of 1600 C) in carefully controlled sintering furnaces.

Post Sintering Processes

If the ceramic components have requirements that cannot be obtained by Wunder-Mold’s closely controlled injection mold process, post-sintering surface grinding, honing, drilling or other secondary operations may be required to achieve the final dimensions. This will ensure that the component produced is exactly what the customer needs.

Inspection

Using state-of-the-art inspection equipment and procedures, the molded parts are verified to Wunder-Mold’s exacting standards. This is done throughout the manufacturing process to ensure the components are of high quality and meet the customer’s requirements, every time.

A sample of materials we offer can be viewed at the Materials page.