Polyphenylene Sulfide-Based Compositions with Solid Fillers for Powder Injection Molding

Powder Injection Molding (PIM) is a versatile manufacturing technology widely used for fabricating components with complex geometries from metals and ceramics, yet its application to high-performance thermoplastics remains underutilized. This study explores the feasibility of manufacturing products from Polyphenylene Sulfide (PPS)-a promising linear aromatic polymer synthesized in powder form-using PIM technology and investigates the development of PE-based feedstocks with PPS and solid fillers. Regarding the matrix formulation, it was found that using pure paraffin as a binder limited the maximum PPS content to 20%. Consequently, a modified binder system consisting of Low-Density Polyethylene (LDPE) and paraffin in a 70:30 wt.% ratio was utilized, which successfully increased the PPS loading in the feedstock to 50% and enabled stable molding. Following matrix optimization, the study examined composites incorporating various fillers, including chalk, talc, and carbon fibers. Systematic rheological analysis confirmed that these composite suspensions possess characteristics necessary for molding products with complex geometries. Key results indicate that optimal sintering conditions were established to achieve the required mechanical properties. Among the tested fillers, carbon fibers were the most effective reinforcement, increasing the elastic modulus by 33% and flexural strength by 20%. Representative examples of samples successfully manufactured via this approach are presented.