SFB 499:  Design, Production and Quality Assurance of Molded Microparts Constructed of Metals and Ceramics

• Subject Area: Materials Science and Engineering ; Mechanical and Industrial Engineering ; Materials Science and Engineering
• Term: from 2000 to 2011
• Project identifier: Deutsche Forschungsgemeinschaft (DFG) - Project number 5484131

Microsystems and miniaturization technology are regarded as key technologies for the future. Available production technology is mainly adapted from the micro electronics industry and therefore is limited to a very small pallet of materials, two-dimensional geometries and is only economical for mass fabrication. The goal of the collaborative research centre 499 is to develop production technology for real three dimensional geometries in micro dimensions in small and medium lot sizes in a broad spectrum of materials. In order to guarantee a fast technology transfer to industry the whole process chain, starting from the design and ending with the quality assurance is regarded from the very beginning of this project.

• DFG Programme: Collaborative Research Centres

Completed projects

• A01 - Design Support Methods for Micromechanical Systems (Project Head Albers, Albert )
• A02 - Modeling - Modeling of Molded Micro Components and Micro Mechanical Systems made of Metallic and Ceramic Materials (Project Head Albers, Albert )
• A03 - Prototyping - development of production processes for prototypes and small series of high strength ceramic micro components (Project Heads Bauer, Werner ;  Knitter, Regina )
• A04 - Simulation of MicroPIM and micro casting - Simulation of microscale primary shaping for the center for integrated micro production: automatization and enhancement of the particle simulator (Project Heads Greiner, Andreas ;  Korvink, Jan Gerrit )
• B01 - Feedstock - Feedstock development for 1C- and 2C-Micro-powder injection molding (Project Heads Hanemann, Thomas ;  Haußelt, Jürgen )
• B2 - Zerspanende Fertigung dreidimensional mikrostrukturierter Formeinsätze (Project Head Schmidt, Jürgen )
• B3 - Prozeßüberwachung der Mikrozerspanung (Project Heads Schmidt, Jürgen ;  Spath, Dieter )
• B04 - Micro-EDM - Economic and reliable manufacturing of micro-molds using EDM (Electro-discharge machining) (Project Head Schulze, Volker )
• B05 - Optimized Moulds - Optimization of Micro-moulds by mechanical and chemical treatments (Project Heads Löhe, Detlef ;  Schulze, Volker )
• B06 - Micro Laser Ablation - Combination of Laser Ablation and EDM (Electric Discharge Machining) for the Manufacturing of threedimensional Micro Molds (Project Head Schulze, Volker )
• C01 - MicroPIM - Manufacturing of metal and ceramic micro parts by powder injection moulding (Project Heads Hanemann, Thomas ;  Piotter, Volker )
• C02 - Development of a casting process for micro components made of metal alloys (Project Heads Haußelt, Jürgen ;  Ritzhaupt-Kleissl, Hans Joachim )
• C03 - Automation - Thermal Sinter-Joining (Project Heads Fleischer, Jürgen ;  Munzinger, Christian )
• C04 - Quality Assurance Customized to Requirements of Micro Process Chains (Project Head Lanza, Gisela )
• C05 - 2C-Micro-PIM - 2-components powder injection moulding in micro dimensions (Project Heads Piotter, Volker ;  Ritzhaupt-Kleissl, Hans Joachim )
• D01 - Micro-Component State - Analysis of the Microstructure, the Residual Stress State, the Hardening State and the Topography of Molded Micro Components (Project Heads Löhe, Detlef ;  Wanner, Alexander )
• D02 - Micromechanical Properties - Behaviour of micro specimens and micro parts at quasistatic and cyclic, uni- and multiaxial loadings (Project Heads Kerscher, Eberhard ;  Kraft, Oliver ;  Lang, Karl-Heinz )
• D03 - Tribology - Reliability of micro components under tribological demands (Project Heads zum Gahr, Karl-Heinz ;  Schneider, Johannes )
• D04 - Verschleißsimulation und Lebensdauervorhersage von mechanischen Mikrosystemen aus urgeformten Bauteilen (Project Heads Huber, Norbert ;  Kraft, Oliver )
• MGK - Integrated Research Training Group "Design, Production, and Quality Assurance of Molded Microcomponents" (Project Head Kraft, Oliver )
• N01 - Reliability of Molded Microcomponents (Project Head Eberl, Christoph )
• T01 - Strukturkatalog für miniaturisierte Trennprozesse (Project Head Fleischer, Jürgen )
• T02 - Fertigungsnahe Mikro-Qualitätssicherung (Project Heads Fleischer, Jürgen ;  Lanza, Gisela )
• T03 - Verschleißsimulation tribologisch beanspruchter Systeme (Project Heads Huber, Norbert ;  Kraft, Oliver )
• T05 - Fertigung und Charakterisierung von MIM-Stahlbauteilen mit integrierten Membranen (Project Heads Eberl, Christoph ;  Kraft, Oliver ;  Piotter, Volker )
• T06 - Entwicklung einer Methodik zur Erstellung aufwandsoptimierter Prozessketten (Project Heads Bauer, Werner ;  Schulze, Volker )
• Z - Zentrale Aufgaben für den SFB (Project Head Schmidt, Jürgen )
• Z01 - Central Task of the Collaborative Research Center (Project Head Kraft, Oliver )
• Z02 - Design and Demonstrator - Execution of design services and coordination of the Center of Integrated Micro Manufacturing (ZIM) (Project Head Albers, Albert )
• Z03 - Moulds and specimens - Centralised allocation of moulds and specimen (Project Head Schulze, Volker )

• Applicant Institution: Karlsruher Institut für Technologie (KIT) ; Campus Süd (aufgelöst)
• Participating Institution: Karlsruher Institut für Technologie
• Participating University: Albert-Ludwigs-Universität Freiburg
• Spokesperson: Professor Dr. Oliver Kraft