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Traditional application for metal injection molding or ceramic injection molding have been small net shaped parts exhibiting design and economic benefit over wrought or cast components. A new water based agar binder system for metal and ceramic injection molding has been developed that offers the ability to produce large thick parts in range of 1 to 2 kg which are competitive with those produced by investment casting. Other significant advantages of this system are a clean and rapid debind and the ability to mold into soft tooling. As a result, savings are achieved not only by eliminating machining and other processing steps but also by reduced development and inventory costs. This technology is applied to a variety of automotive applications such as; EGR System, Exhaust System, Oxygen Sensors, Electrical Components, Engine Components, etc. Many of these applications require demanding mechanical properties.

There are many advantages to air intake manifolds molded from Nylon 6,6 Glass reinforced composite material versus a pressure-cast aluminum manifold. Weight is significantly lowered and production costs generally are reduced. Performance improves with the precise control of the interior surface finish and reduced air induction temperatures. The Nylon 6,6 Glass reinforced composite material can be molded into intricate shapes by injection molding or lost-core process with reduced machining operations as well as Nylon 6,6 material is easily recycled. Production costs will continue to decrease as optimization of material, process and part integration increases. This study evaluates Nylon 6,6 Glass reinforced composite material in terms of the intake manifolds material key requirements such as thermal, heat aging, fatigue, impact, creep, stress and chemical resistance including multi fuels.