Assigned a project to create a PIM (Powder Injection Molded) dental implant. Project received a 96% from Powder Metallurgy expert Randall M. German.

1. Workaholics AnonymousKendal Hanel
Bryant Pham
Konstantin Ivanov
Hoang Pham
Robert Scult
Anthony Tilley

2. Problem Statement
 Dental implants are made out
of machined metals
 Top component suffers
excessive wear

3. 16000
3553
2793
4086
5599
2000
SCALE6:1SCALE6:1
CROWN
MATERIAL:
ALUMINA (Al2O3)
IMPLANTPOST
MATERIAL:
CPTITANIUM GRADE1
SECTION A-A
A
DO NOTSCALEDRAWING
POSTAND CROWN
ASSEMBLY
SHEET1 OF4
HOANG PHAM
UNLESSOTHERWISESPECIFIED:
SCALE: 5:1 WEIGHT:
REVDWG. NO.
A
SIZE
TITLE:KONSTANTIN IVANOV
KENDALHANEL
ENGINEERS
FINISH
MATERIAL
INTERPRETGEOMETRIC
TOLERANCING PER: ANSI Y14.5-1994M
DIMENSIONSAREIN UM (MICRO)
TOLERANCES:
LINEAR: 100 MICRONS
ANGULAR: MACH 1
APPLICATION
USED ONNEXTASSY
PROPRIETARY AND CONFIDENTIAL
THEINFORMATION CONTAINED IN THIS
DRAWING ISTHESOLEPROPERTYOF
SDSU. ANYREPRODUCTION
IN PARTORASA WHOLEWITHOUTTHE
WRITTEN PERMISSION OFSDSU
ISPROHIBITED.
5 4 3 2 1
SDSU ENGINEERING
BRYANTPHAM
ANTHONYTILLEY
ROBERTSCULT
ME 596 PIM OF BIO
MEDICAL MINIATURE
N/A
N/A
SolidWorks Student Edition.
For Academic Use Only.

4. Material Selection Criteria
 Available particle size and shape for micro-feature PIM
 Biocompatible
 Wear Resistant
 Low oxygen and carbon content
Final Decision
Post Implant – CP Ti Grade 1
Screw Hate – Al2O3

5. Powder Specifications
AP&C Advanced
Ti Spherical Sieving Apparent
Density
0-25um 32% 2.55
25-45um
65.5%
+45um 2.5%
Inframat Advanced Materials
Al2O3
Spherical
Particle Size Apparent
Density
3-4um Avg. 3.97 g/cm3

6. Manufacturing Process
 Mix powder
 Polypropylene, paraffin wax, and stearic acid binder at 65% solids
loading
 PIM using Archimedes screw heated barrel
 Immerse in heptane at 60°C
 Second stage Argon sweep gas for Titanium at 450°C max
 Vacuum sinter at 1250°C for 3 h for Titanium
 Finish Titanium with hot isostatic pressing
 Sinter at 1400°C for 2 h for Alumina

7. Inspection
 Visual and SEM (appearance)
 Dye penetration (surface cracks)
 Core X-ray (inner core defects)

8. Critical Function
 Improving wear resistance of the component
 Biocompatibility of component
 Removing all machining steps
 Material selection to improve properties
 High wear resistance from Alumina
 Titanium & Alumina fit biocompatibility requirements

9. D
2675
LB2
LB1
ANG C
ANG B
3553
LC1
1000
1992
1250
CONFIG D[UM] LC[UM] LB1[UM] LB2[UM] ANG C[ ] ANG B[ ] VOL
[mm^ 3]
SMALL 3300 1000 4000 3000 10,5,0 10,5,0 62.50
MEDIUM 3500 2000 5000 3000 10,5,0 10,5,0 97.20
LARGE 4000 3000 6000 4000 10,5,0 10,5,0 167.00
A
DO NOTSCALEDRAWING
IMPLANTPOST
GENERALDIMS
SHEET2 OF4
HOANG PHAM
UNLESSOTHERWISESPECIFIED:
SCALE: 8:1 WEIGHT:
REVDWG. NO.
A
SIZE
TITLE:KONSTANTIN IVANOV
KENDALHANEL
ENGINEERS
FINISH
MATERIAL
INTERPRETGEOMETRIC
TOLERANCING PER: ANSI Y14.5-1994M
DIMENSIONSAREIN UM (MICRO)
TOLERANCES:
LINEAR: 100 MICRONS
ANGULAR: MACH 1
APPLICATION
USED ONNEXTASSY
PROPRIETARY AND CONFIDENTIAL
THEINFORMATION CONTAINED IN THIS
DRAWING ISTHESOLEPROPERTYOF
SDSU. ANYREPRODUCTION
IN PARTORASA WHOLEWITHOUTTHE
WRITTEN PERMISSION OFSDSU
ISPROHIBITED.
5 4 3 2 1
SDSU ENGINEERING
BRYANTPHAM
ANTHONYTILLEY
ROBERTSCULT
ME 596 PIM OF BIO
MEDICAL MINIATURE
CP TITANIUM GRADE1
FREEOFBURRSAND DEFECTS
SolidWorks Student Edition.
For Academic Use Only.

10. A
B
C
SECTION A-A
200 PITCH
150 HEIGHT
DETAILA
SCALE25 : 1
200 PITCH
116 HEIGHT
DETAILB
SCALE25 : 1
500 PITCH
255 HEIGHT
DETAILC
SCALE20 : 1
VOLUME: 70.00 mm^ 3
A
DO NOTSCALEDRAWING
IMPLANTPOST
THREAD DETAIL
SHEET3 OF4
HOANG PHAM
UNLESSOTHERWISESPECIFIED:
SCALE: 10:1 WEIGHT:
REVDWG. NO.
A
SIZE
TITLE:KONSTANTIN IVANOV
KENDALHANEL
ENGINEERS
FINISH
MATERIAL
INTERPRETGEOMETRIC
TOLERANCING PER: ANSI Y14.5-1994M
DIMENSIONSAREIN MM
TOLERANCES:
FRACTIONAL
ANGULAR: MACH 1 BEND
TWO PLACEDECIMAL .02
THREEPLACEDECIMAL .005
APPLICATION
USED ONNEXTASSY
PROPRIETARY AND CONFIDENTIAL
THEINFORMATION CONTAINED IN THIS
DRAWING ISTHESOLEPROPERTYOF
SDSU. ANYREPRODUCTION
IN PARTORASA WHOLEWITHOUTTHE
WRITTEN PERMISSION OFSDSU
ISPROHIBITED.
5 4 3 2 1
SDSU ENGINEERING
BRYANTPHAM
ANTHONYTILLEY
ROBERTSCULT
ME 596 PIM OF BIO
MEDICAL MINIATURE
FREEOFBURRSAND DEFECTS
CPTITANIUM GRADE1SolidWorks Student Edition.
For Academic Use Only.

11. R400
4086
10.00°
2000 2000
1737
5599
14.00°
2300
1000
2283
1550
8000
2000
A
SECTION A-A
200 PITCH
150 HEIGHT
375
DETAILA
SCALE50 : 1
A
DO NOTSCALEDRAWING
CROWN
SHEET4 OF4
HOANG PHAM
UNLESSOTHERWISESPECIFIED:
SCALE: 8:1 WEIGHT:
REVDWG. NO.
A
SIZE
TITLE:KONSTANTIN IVANOV
KENDALHANEL
ENGINEERS
FINISH
MATERIAL
INTERPRETGEOMETRIC
TOLERANCING PER: ANSI Y14.5-1994M
DIMENSIONSAREIN UM (MICRO)
TOLERANCES:
LINEAR: 100 MICRONS
ANGULAR: MACH 1
APPLICATION
USED ONNEXTASSY
PROPRIETARY AND CONFIDENTIAL
THEINFORMATION CONTAINED IN THIS
DRAWING ISTHESOLEPROPERTYOF
SDSU. ANYREPRODUCTION
IN PARTORASA WHOLEWITHOUTTHE
WRITTEN PERMISSION OFSDSU
ISPROHIBITED.
5 4 3 2 1
SDSU ENGINEERING
BRYANTPHAM
ANTHONYTILLEY
ROBERTSCULT
ME 596 PIM OF BIO
MEDICAL MINIATURE
ALUMINA [Al2O3]
FREEOFBURRSAND DEFECTS
SolidWorks Student Edition.
For Academic Use Only.

12. Market Shares
 Estimated $3.4 Billion in implant sales a year & growing at
10%/year
 “American Academy of Implant” estimated 3 million people
with implants and 500k increase/year in US
 69% of adults (age. 35-44) have lost at least 1 permanent
tooth
 By age 74, 26% of adults will have lost all of their permanent
teeth.
 Europe ½ global market, while North America 2nd largest
region
 Growth in the Asia/Pacific region being driven by China & is
expected to increase the global size in coming years.
 15% Market Share @ 3 Implants/person
 225,000 units/year

13. Failure Criteria
 Does not fit dimensional tolerance
 Unnecessary secondary finishing operations
 High oxygen or carbon content
 Low volume production
 No profit
 Unacceptable defects

14. Equipment Cost
 Wittmann Battenfeld Molding Machine + Robot
$130,000
 Scott Turbon Mixer Inc. Double Planetary Mixer
 Ipsen Vacuum Debind/Sinter Furnace

15. Production Cost
 $15,000 Mold made in China
 HIP contracted to Pressure Tech Inc. @ $2000/cycle
 Part Volume
 Post 0.173cm3
 Cap 0.128 𝑐𝑚3
 0.73179 g/unit Ti @ $150/kg
 0.5052445 g/unit Alumina @ $26/kg
 $0.15/unit material
 $0.23/unit processing
$0.38/unit total

16. References
 http://www.wittmann-
ct.com/lib/f_dbstream.php?tn=tab_file&fd=file&mt=application/pdf&id=1079&hxfile&
f=YearEnd2012.pdf
 http://www.dental-
tribune.com/articles/business/americas/11737_dental_implants_market_expected_t
o_double_by_2018.html
 http://www.raymor.com/apc/products/titanium/#gr-1_0-45
 American Association of Oral and Maxillofacial Surgeons
 http://www.pressuretechnology.com/hot-isostatic-pressing.php
 http://www.ncbi.nlm.nih.gov/pubmed/17257912
 http://www.sciencedirect.com/science/article/pii/S0965997809001367
 http://link.springer.com/article/10.1007%2Fs11837-011-0036-z