A suitable and cost-effective microfabrication technique for processing aluminum micropart is required, as the choice
of aluminum microparts for aerospace, electronics and automobile components is preferred over other metals due to its
excellent properties. Meanwhile, powder injection molding (PIM) is identified as an economical manufacturing technique
for processing ceramic and micro-metal powders into microparts and or components. Therefore, this study investigates
formulation and processing of aluminum PIM feedstock using a custom-made machine. The investigation is focused on
the effect of mixing process parameters (powder loading, rotor speed and mixing temperature) and the suitability of
the backbone polymer. The formulated PIM feedstock constituents are paraffin wax (PW), stearic acid (SA), high-density
polyethylene (HDPE)/ medium-density polyethylene (MDPE) alternatively and aluminum micro-metal powder. Taguchi
method is used for the design of experiments (DOEs) and analysis. In addition, response surface methodology (RSM) is
employed to develop empirical viscosity models. The optimum powder-binder mixing ratio of 58:42 vol. % with rotor
speed of 43 rpm were determined for preparing aluminum PIM feedstock using mini-lab mixer developed. The empirical
model developed for aluminum PIM feedstock viscosity shows a good fit with R2
values of 0.84 using HDPE and 0.96 for
MDPE binder system. This investigation demonstrates preparation and suitability of aluminum PIM feedstock using waxbased
binder system.