Material spotlight: Kovar

One of the key benefits of metal injection moulding (MIM) 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.

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.

Low coefficient of thermal expansion

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.

This property makes Kovar ideal for electronics and semiconductor applications, 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.

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.

Aerospace alloy of choice

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.

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.

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.

Why choose Kovar from OptiMIM

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.

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.

Typical applications of Kovar

• Hermetic electronic housings and feedthroughs
• Radar and satellite components
• Optical sensor mounts
• Sealed connectors and relays
• High-precision instrumentation parts

Experience the OptiMIM advantage

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. 

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.