Innovative Microforming Technologies to Manufacture Miniaturized Components

Microforming is an emerging micro-manufacturing technique that enables mass manufacturing of various miniaturized micro-components to serve the biomedical, MEMS, and other relevant sectors. At present, microforming technology is in a very nascent stage, limited to easy-to-deform FCC materials such as Aluminum and Copper alloys. In the present scenario, the biomedical sector is mainly dominated by Titanium (Ti) and Magnesium (Mg) alloys. To serve the emerging demand for biomedical parts and implants, the microforming of materials such as Ti and Mg alloys must be studied. Owing to HCP crystallography, the microforming of such complex materials requires deformation at elevated temperatures to activate temperature-dependent slip systems. This needs a thoughtful understanding of material design, microstructural engineering, sophisticated micro-tooling design, and process optimization. Superplasticity, a special case studied during hot deformation of Mg and Ti alloys at the macroscale, enables them to undergo extensively large plastic deformation without necking/failure. The present research aims to establish a roadmap to facilitate the innovative microforming technologies to manufacture difficult to form engineered Mg and Ti alloys on developing different micro products such as microcups, micro-pins, micro-gears, micro-channels etc. The study of innovative microforming technologies of complex Mg and Ti alloys can revolutionize the bio implant manufacturing sector and drastically cut down manufacturing costs. The micro product specific knowledge base for the innovative microforming technologies are established using various mechanical and microstructural assessments.

Keywords: Microforming, Superplastic Microforming, Bioimplant Manufacturing, Magnesium alloys, Titanium alloys, Biocompatibility.