Answer to Question 1
Poker chipping occurs in the ram extrusion process when the charges of compacted resin are not well bonded together. The billet made by the ram extrusion process can therefore be in separate charge portions. These are compacted together like discs or poker chips. This problem can be prevented by improving the consolidation between charges, usually done most easily by increasing the fusion temperature.
Answer to Question 2
In conventional sintering the shape of the part is determined by the preforming mold. Since the main purpose of preforming is to eliminate voids and compact the material, high pressures are required and the ability to press the powdered material into complicated shapes is compromised. In coining, the part is placed
into a mold when the part is in a softened state. Therefore, pressing into a detailed shape is much easier.
Answer to Question 3
The area ratio of 1:2 indicates that the thickness will be reduced from 2 mm to 1 mm in the final part, assuming that the wall thicknesses are uniform. Uniform wall thicknesses are not likely with thermoforming and so some portions of the walls will be much thinner than the required 1 mm and will be likely to rupture when drawn.
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