Ultrasonic Mixer b Members: Lihong Xu »Moshe Solomon »Joanna Pirnot »Katie Kaser Mission: Design a system incorporating a suitable non-mechanical device for homogenizing powder injection molding feedstocks into relatively high viscosity liquids, by April 1999 Customer: Fraunhofer Advisor: Dr. Keefe Approach: Use the Engineering method, and identify wants and constraints, to select the best concept to complete our mission

b Introduction and Background - Katie Kaser b Benchmarking (Mechanical Mixer) - Joanna Pirnot b Benchmarking (Ultrasonic Mixer) - Lihong Xu b Schedule and Budget - Moshe Solomon

Powder Injection Molding (PIM) Metal or ceramic powder Polymer matrix Wetting agent PIM Feedstock

Importance of Quality Mixing Non-uniform Distribution Removal of Polymer Voids or defects

Current Situation b Mechanical Mixers b Mixing Difficult b Wear and tear

Innovation... Ultrasonic Energy Source Ultrasonic products out there

Benchmarking b Mechanical Mixers b Ultrasonic Mixers

Mechanical Mixer b Advantages Produce homogenous PIM feedstockProduce homogenous PIM feedstock TemperatureTemperature Material introduction and extractionMaterial introduction and extraction SensorsSensors

Mechanical Mixer b Disadvantages MaintenanceMaintenance CostCost SizeSize

Ultrasonic Mixer b Probe or horn How they workHow they work Things to considerThings to consider

Ultrasonic Mixers on the Market b Sonolator - Sonic Corp. (Stratford, CT) b Near Field Acoustical Processor –Advanced Sonic Processing Systems (Oxford, CT)

Principle of the Mixers b Sonolator b Near Field Acoustical Processor

Advantages b Low Initial Investment b Low Operation Cost High EfficiencyHigh Efficiency Low maintenanceLow maintenance Easy cleaningEasy cleaning b No Cross Contamination b Precise performance

Disadvantages b Viscosity Range b Temperature Range

SENIOR DESIGN SCHEDULE S E P T E M B E RO C T O B E R BENCHMARKING Contact Manufacture Ultrasonic Mixers Mechanical Mixers Contact Ultra Consultants Contact People in industry FIRST MEETINGS Define Project Collected list of Wants Saw Existing Equipment Introduced to the Process PROPOSAL Written Report Presentation BRAINSTORM Process Energy Requirements Research Ultrasonic Equipment Mobile/Stationary Contamination Maintenance Operation Detail Volume Wants/Constraints Existing Mixer Lab Access MEETING WITH CUSTOMER ESTABLISH METRICS PROGRESS REVIEW