MII TECHNOLOGIES ENTERS CERAMICS MANUFACTURING.

Mii Technologies, LLC., West Lebanon. N.H., a leader in the powder-metal manufacturing field, has expanded the use of its award-winning technology to produce complex-geometry parts from ceramic material.

This development dramatically adds to the scope of applications for the uses of Mii's net and near-net shape parts production capacities. Using the same fully digital system that has won Mii success in the metal arena, the company has demonstrated manufacturing parts from ceramic material with strikingly higher density (at 50 TSI in initial production runs, with a potential of 65 TSI), extraordinary mechanical uniformity and at net-shape standards not approached before.

The entry of Mii to the ceramics manufacturing industry brings an array of new technology to the field. This technology, tested with "extremely positive" initial results by The Ferro Corporation, opens a wide range of applications for ceramic manufacturing, greatly expanding the "design envelope" for ceramic materials. Mii's new compaction system, embodied in a set of presses that are available 12 to 20 weeks after receipt of order, won a grand prize for outstanding application for powder metallurgy from the Metal Powder Industries Federation for its first commercial part. The company's press technology was named an "Invention of the Year" by TIME Magazine for the year 2000, one of only three selected.

For ceramic manufacturers, they make possible the following:

-- A far wider range of parts that can be manufactured cost-effectively. Mii has highly customizable press technology with standard configurations offering as many as eight levels -- three punches up and three down, with independently actuated core and die.

-- A standard of net-shape manufacturing not now reached in the ceramics industry. Highly dense green parts of complex geometries can be fired and shipped without additional machining. The pressing is monitored in real time by digital sensors that track and guide the process, providing both quality control and quality monitoring and allowing for true "lights-out manufacturing."

-- Highly consistent part densities. The material going into the die is measured by weight, not by volume, assuring weights consistent to within +/- 0.1 grams, and as finely as +- 0.04 grams, regardless of the size of the part. The material is then distributed evenly throughout the die prior to pressing by a patented process called "fluidization" so the resulting parts are highly uniform one to another. This dramatically minimizes density gradients in each part.

-- Much greater pressing loads. This carefully calibrated measuring and fluidization system - coupled with digitally-controlled hydraulic presses -- makes it possible to press parts to higher densities and tighter tolerances. This results in parts with much greater green strength, lower and more uniform shrinkage, and minimal ejection/deflection cracking.

"The challenges of net-shape ceramic manufacturing provide a wonderful match for the problems we have wrestled with, and solved, in metal powder manufacturing for many years," said Alan Beane, CEO of Mii Technologies. "Mii is fundamentally about two things: understanding particulate materials and thinking innovatively about how to make those materials into things. We're pleased that we can put in the hands of ceramic engineers a set of tools that substantially broadens their abilities."

"For Ferro, advances in pressing are extremely important, since our customers often ask us to investigate complex parts that, unfortunately, we just cannot manufacture using traditional technologies," explained David R. Banfield, business manager for Ferro's North American Ceramic Division.

"Although we are only just beginning our relationship with Mii Technologies, our initial findings have been extremely positive," he added. "Although further research and collaboration with Mii is necessary, Ferro may soon be able to press even the most complex shapes requested by our customers, including some that currently would not be possible using existing technologies. If we succeed, Ferro will be able to offer unique new products with significant added value to our customers."

The Mii compaction system was first unveiled for the powder metal industry last year. The system incorporates dozens of innovations, yet it stands a small fraction the size of a conventional press. Moreover, it employs a unique "docking station" architecture that allows each press to be plugged into the hydraulic and electric power, digital controls and materials supply needed to operate. The system has been in use at Mii to manufacture soft magnetic and high strength steel net shape parts from Mii metal powders for more than 18 months.

About Mii

Mii is a leader in the development of innovative manufacturing technologies, materials and materials processing techniques for the production of net-shape parts, whether from metal, ceramic or plastic powders. The company is the technology leader in the world for electromagnetics where its materials and net-shape manufacturing technology are enabling for applications involving high frequency, high power density energy conversion into physical work, such as fast solenoid/valve actuators, highly efficient motors, motor generators/alternators, speaker systems, ignition coils, etc. Mii, based in West Lebanon, NH, is privately held.

For more information, call 781/648-2564.