Ensure quality by implementing key improvements from the start

<p>From concept to completion, optimising your MIM part with the right improvements is essential for developing an exceptional component.</p>

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Part improvement

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Improving the design and specifications of the metal injection mould early in the MIM process is crucial for enhancing overall part quality and ensuring optimal performance.

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Enhanced product quality

Enhancing parts through Design for Manufacturing (DFM) reduces the risk of defects and ensures greater product reliability.

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Reduced risk of defects

Addressing part issues early in the process streamlines production, cutting lead times and accelerating time to market.

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Accelerated time to market

Recognising and resolving potential issues early prevents expensive rework and reduces scrap.

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Cost reduction

How do part improvements drive project success?

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Our engineers design optimised components with precise material placement, enhancing part quality and precision through coring and mass reduction techniques.

Uniform wall thickness, coring and mass reduction

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Holes and slots can be easily produced with MIM, offering reduced part mass, improved wall-thickness uniformity and minimal additional cost; perpendicular holes are the most cost-effective.

Holes and slots

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MIM readily creates external undercuts, increasing design flexibility. Internal undercuts are possible but may require complex solutions and engineering expertise.

Undercuts

Integrated threads, both internal (using unscrewing cores) and external (moulded, sometimes requiring a parting-line flat), streamline production and improve engagement.

Internal and external moulded threads

MIM allows detailed features such as knurling, lettering, logos and date coding to be added directly to components without affecting cost, demonstrating its versatility in complex metal part design.

Knurling, lettering and logos

Heat treatment enhances the strength and hardness of MIM parts. Carbon, alloying elements and porosity influence hardening.

Heat treatment

Our approach to defect-free production

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<p>One of the key <a href="/metal-injection-molding/benefits" target="_self">benefits of metal injection moulding (MIM)&nbsp;</a>is the wide selection of alloys available to meet specific design, performance and cost requirements. MIM technology enables precise customisation of alloy compositions to achieve the exact material properties required for a customer’s unique application.</p><p>Kovar, also known as MIM-F15, is one of the leading alloys offered by OptiMIM. This iron-nickel-cobalt alloy is recognised for its outstanding stability across temperature changes, making it a leading choice for industries where precision, reliability and durability are critical.</p><h2>Low coefficient of thermal expansion</h2><p>Kovar, or F-15 alloy, is a low-expansion iron-based alloy engineered to maintain dimensional stability across extreme temperature variations. Its unique composition—rich in nickel and cobalt—minimises thermal expansion, enabling it to bond seamlessly with glass and ceramics.</p><p>This property makes Kovar ideal for <a href="/industries/consumer-electronics" target="_self">electronics and semiconductor applications</a>, where even minor thermal shifts can affect performance. It is widely used in metal-to-glass sealing, hermetic packaging and sensor housings, providing an airtight barrier that protects sensitive components from moisture and environmental damage.</p><p>Because of its low coefficient of thermal expansion (CTE), Kovar ensures long-term stability and performance in devices that must maintain precise tolerances under fluctuating conditions.</p><h2>Aerospace alloy of choice</h2><p>In recent years, Kovar has become a preferred material in aerospace and defence applications. Its ability to withstand rapid temperature extremes, from absolute zero to extremely high temperatures, without losing structural integrity makes it invaluable in high-performance systems.</p><p>For example, Kovar components are used in radar systems, satellite assemblies and sensor mounts, where even minimal warping or distortion could cause equipment failure. Its dimensional stability ensures that sensitive instruments maintain calibration and performance, even under the most demanding thermal cycles.</p><p>Whether in aerospace, defence or advanced electronics, Kovar’s performance in demanding conditions makes it a trusted choice for engineers who require consistency and precision.</p><h2>Why choose Kovar from OptiMIM</h2><p>OptiMIM specialises in custom MIM manufacturing using advanced materials such as Kovar. Our process ensures tight tolerances, superior surface finish and repeatable precision—ideal for industries where component accuracy is critical.</p><p>By leveraging metal injection moulding, we produce complex geometries that would be difficult or costly to machine from conventional wrought Kovar. This results in high-performance parts with exceptional cost efficiency, designed to meet the most demanding application standards.</p><h4>Typical applications of Kovar</h4><ul><li>Hermetic electronic housings and feedthroughs</li><li>Radar and satellite components</li><li>Optical sensor mounts</li><li>Sealed connectors and relays</li><li>High-precision instrumentation parts</li></ul><h3>Experience the OptiMIM advantage</h3><p>OptiMIM’s expertise in metal injection moulding with Kovar and other advanced alloys enables engineers to achieve high-precision results with minimal waste and optimal material performance.&nbsp;</p><p>Whether you require prototypes or high-volume production, our team can help you design, engineer and manufacture components that perform reliably in the harshest environments.</p>

Aerospace satellite with kovar metal parts

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Discover the unique thermal expansion properties of Kovar alloy and why it is ideal for high-reliability electronics and demanding aerospace applications.

Material spotlight: Kovar | OptiMIM article

Kovar, a low-expansion iron alloy used in electronics and aerospace, is a metal injection moulding (MIM) material that withstands extreme temperatures without structural change, making it ideal for applications such as radar systems and satellites. 

Material spotlight: Kovar

<p>Both investment casting and metal injection moulding produce strong, precise metal components, but key differences can make one process better suited to specific applications.</p><p><a href="/metal-injection-molding" target="_self">Metal injection moulding (MIM)</a> creates extremely dense, net-shape parts, offering scalability and cost-effectiveness compared with traditional machining. Investment casting provides unmatched alloy selection and enables complex part geometries at various production volumes.</p><p><strong>Join this webinar to learn more about:</strong></p><ul><li>Material options for each process</li><li>Achievable tolerances</li><li><a href="/industries/medical" target="_self">Medical/dental case studies</a></li><li><a href="/industries/defense" target="_self">Aerospace/defence applications</a></li><li>Production volumes</li><li>Surface finishes</li></ul><p><strong>Complete the form to register for this free webinar!</strong></p>

Investment casting machine dipping mold into slurry

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Compare investment casting and MIM for complex metal parts, with key differences in tolerances, costs, materials and production scalability explained clearly.

Investment casting vs. metal injection moulding

This webinar compares and contrasts investment casting and metal injection moulding, examining material options, tolerances and applications in the medical/dental and aerospace/defence industries, with case studies and a discussion of volumes and surface finishes. 

Investment casting vs. metal injection moulding: a process comparison

<p>Manufacturing is complex – small metal components can present a challenge to engineers when material density, design flexibility and wall thickness are constrained. If you are looking for high-quality, complex, precision metal components weighing less than 160 grams, then OptiMIM’s metal injection moulding process may be the best option.</p><p>Metal injection moulding, or MIM, is a process that combines two established technologies: plastic injection moulding and powder metallurgy. <a href="/additional-capabilities/engineering" target="_self">OptiMIM engineers</a> can create geometrically complex, dense parts that cannot be produced using conventional powder metallurgy processes without secondary machining. With MIM, it is possible to integrate and consolidate several components into a single moulded piece, freeing designers from the traditional constraints associated with assembling several separately cast parts to achieve a net-shape component.</p><p>Our designers know that MIM is not for everyone. With so many metalworking solutions available, it can be difficult to determine when a project can benefit from the MIM process. We have compiled five frequently asked questions to help you decide whether MIM is the right process for you.</p><h2>Which materials are used in metal injection moulding?</h2><p>MIM materials have had their chemical compositions modified to withstand the complex metal injection moulding process. There are a wide variety of <a href="/materials" target="_self">materials available for MIM</a>, but we specialise in stainless steel, copper and low-alloy steel materials. We can also process other specialist or custom materials tailored to your mechanical property specifications.  Ask an engineer about our custom feedstock capabilities!</p><h3>What part sizes are most suitable for metal injection moulding?</h3><p>It is also crucial to consider the parting line and its witness mark. Every part has a parting line related to the moulding process. However, it is important to consider the application and understand how the location of the parting line might affect the <a href="/resources/article/what-makes-a-good-fit-for-mim" target="_self">part's form, fit or function</a>. Ideally, the parting line should not be on a functional surface.</p><h3>What is the porosity of metal injection moulding components?</h3><p>Unlike other casting processes, MIM offers very high density with a uniform, fine grain structure. Typical MIM part density reaches 95-98%, however, some material applications with secondary hot isostatic pressing (HIP) can achieve near-wrought material density.</p><h3>What minimum and maximum wall thicknesses can metal injection moulding achieve?</h3><p>Wall thickness is contingent upon wall length, overall part size and part design. If the wall is localised, wall thicknesses of 0.01” or less are possible. At the other end of the spectrum, wall thicknesses of up to 0.5” are possible. It is important to note that as wall thickness increases, so do moulding process cycle time, material consumption, and debinding and sintering cycles, which inherently increase total part cost.</p><h3>How do you allow for shrinkage in mould design?</h3><p>Over the years, we have studied each material used in the MIM process extensively. Each alloy and geometry shrinks differently. We developed and use predictive models and factor this into our tooling design.</p>

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Find answers to common questions about MIM processes, tolerances, materials and cost benefits in OptiMIM’s metal injection moulding FAQ online resource.

Metal injection moulding FAQ | OptiMIM article

Metal injection moulding (MIM) is a cost-effective process for producing complex, small metal components with high density and tight tolerances, making it a suitable alternative to traditional metalworking processes for the right applications. 

Metal injection moulding FAQ

Expand your knowledge of OptiMIM part improvement

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Part improvement

Our approach to defect-free production

Uniform wall thickness, coring and mass reduction

Holes and slots

Undercuts

Internal and external moulded threads

Knurling, lettering and logos

Heat treatment

Beyond the basics

Expand your knowledge of OptiMIM part improvement

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