Optimisation of Process Conditions in Powder Injection Moulding of Microsystem Components using Robust Design Method Part 2 – Secondary Design Parameters

Powder injection moulding (PIM) is a proper fabrication method for microsystem technology components. This paper studies the process control of PIM to create thin walled, high aspect ratio geometries, which can be easily found in microtechnology based electro chemical, mechanical and biological systems (MECS). The powder used in this study is gas atomised 316L stainless steel with a median particle size of 10 mm. The effects of reducing the thickness of high aspect ratio geometries on the secondary design parameters including the maximum wall shear stress, cooling time and standard deviations of the melt front velocity and areas are studied. The study shows process parameters including fill time, feedstock injection temperature, mould wall temperature and switchover position can be optimised using the Taguchi robust design method.X1177sciescopu

OPTIMISATION OF PROCESS CONDITIONS IN POWDER INJECTION MOULDING OF MICROSYSTEM COMPONENTS USING A ROBUST DESIGN METHOD: PART I. PRIMARY DESIGN PARAMETERS

Powder injection moulding (PIM) is a net fabrication technique that combines the complex shape forming ability of plastic injection moulding, the precision of die casting, and the material selection flexibility of powder metallurgy. For this study, the design issues related to PIM for the fabrication of thin walled, high aspect ratio geometries were investigated. These types of geometries are typical to the field of microtechnology based electro chemical, mechanical and biological systems, which are multiscale (sizes in at least two or more different length scale regimes) fluidic devices working on the principle of heat and mass transfer through embedded micro- and nanoscale features. Stainless steel was the material chosen for the investigations because of its high temperature resistivity and chemical inertness necessary for typical microfluidic applications. The investigations for the study were performed using the state of the art computer aided engineering design tool, PIMSolver. The effect of reducing part thickness on the process parameters, including melt temperature, mould temperature, fill time and switchover position, during the mould filling stage of the injection moulding cycle was investigated. The design of experiments was conducted using the Taguchi method. It was found that the process variability generally increased with reduction in thickness. Mould temperature played the most significant role in controlling the mould filling behaviour as the part thickness reduced.X1115sciescopu

Adjustable Robust Parameter Design with Unknown Distributions

Abstract This article presents a novel combination of robust optimization developed in mathematical programming, and robust parameter design developed in statistical quality control. Robust parameter design uses metamodels estimated from experiments with both controllable and environmental inputs (factors). These experiments may be performed with either real or simulated systems; we focus on simulation experiments. For the environmental inputs, classic robust parameter design assumes known means and covariances, and sometimes even a known distribution. We, however, develop a robust optimization approach that uses only experimental data, so it does not need these classic assumptions. Moreover, we develop `adjustable' robust parameter design which adjusts the values of some or all of the controllable factors after observing the values of some or all of the environmental inputs. We also propose a new decision rule that is suitable for adjustable integer decision variables. We illustrate our novel method through several numerical examples, which demonstrate its effectiveness.

Serious Asthma Events with Fluticasone plus Salmeterol versus Fluticasone Alone

BACKGROUND: The safe and appropriate use of long-acting beta-agonists (LABAs) for the treatment of asthma has been widely debated. In two large clinical trials, investigators found a potential risk of serious asthma-related events associated with LABAs. This study was designed to evaluate the risk of administering the LABA salmeterol in combination with an inhaled glucocorticoid, fluticasone propionate. METHODS: In this multicenter, randomized, double-blind trial, adolescent and adult patients (age, ≥12 years) with persistent asthma were assigned to receive either fluticasone with salmeterol or fluticasone alone for 26 weeks. All the patients had a history of a severe asthma exacerbation in the year before randomization but not during the previous month. Patients were excluded from the trial if they had a history of life-threatening or unstable asthma. The primary safety end point was the first serious asthma-related event (death, endotracheal intubation, or hospitalization). Noninferiority of fluticasone-salmeterol to fluticasone alone was defined as an upper boundary of the 95% confidence interval for the risk of the primary safety end point of less than 2.0. The efficacy end point was the first severe asthma exacerbation. RESULTS: Of 11,679 patients who were enrolled, 67 had 74 serious asthma-related events, with 36 events in 34 patients in the fluticasone-salmeterol group and 38 events in 33 patients in the fluticasone-only group. The hazard ratio for a serious asthma-related event in the fluticasone-salmeterol group was 1.03 (95% confidence interval [CI], 0.64 to 1.66), and noninferiority was achieved (P=0.003). There were no asthma-related deaths; 2 patients in the fluticasone-only group underwent asthma-related intubation. The risk of a severe asthma exacerbation was 21% lower in the fluticasone-salmeterol group than in the fluticasone-only group (hazard ratio, 0.79; 95% CI, 0.70 to 0.89), with at least one severe asthma exacerbation occurring in 480 of 5834 patients (8%) in the fluticasone-salmeterol group, as compared with 597 of 5845 patients (10%) in the fluticasone-only group (P<0.001). CONCLUSIONS: Patients who received salmeterol in a fixed-dose combination with fluticasone did not have a significantly higher risk of serious asthma-related events than did those who received fluticasone alone. Patients receiving fluticasone-salmeterol had fewer severe asthma exacerbations than did those in the fluticasone-only group