Utilising MIM for large-scale manufacturing

Producing a high-quality part in a short production time and at the lowest total cost is crucial to the overall success of a company and its final component. For manufacturing small, complex components at scale, metal injection moulding (MIM) is the most efficient process for the job.

At OptiMIM, we are experts in taking your project from the drawing board through to mass production. Not only does our metal injection moulding process lend itself to scalability through automation, large batch capacity and relatively low up-front investment, but our engineers are experts in streamlining your supply chain and validation processes.  

To answer your questions about why metal injection moulding is ideally suited to manufacturing at scale, we spoke with OptiMIM Business Development Manager John O'Donnell, a Mechanical Engineer with over 30 years of industry experience specialising in product design and development.

Why is it important to manufacture at scale?

We often discuss the importance of designing for manufacturability (DFM), but scalability must likewise be at the forefront of product design. After considering early supplier involvement and transparency, incorporating scalability into the process enables us to build tooling that supports a sudden surge in production demand or modifications to design features. By consulting our design engineers early in the part development process, we can better understand the variables and develop a roadmap that works for the customer and delivers a successful market-ready component.

How do I scale production with control?

There are several areas in which suppliers can fall short when delivering a quality part—such as failing to plan for potential manufacturing disruptions or volume changes. It is important to consider the entire life of the project and create a roadmap. During roadmap development, documenting process variables is key to success. The process should focus less on getting parts to a customer as quickly as possible and more on structuring the entire process and reducing lead times over time. Emphasising the documentation of procedures and training prevents the loss of knowledge about key steps and controls as production increases. Manufacturers must be able to pivot and adapt to the unexpected, and with the right processes in place, success is inevitable.

How can I increase production volume?

Using scaling techniques, such as Predictive CPK Modelling, can ensure volume increases are implemented effectively and efficiently. Tolerances and dimensions are analysed to determine the level of CPK, or sustained process capability, that can be maintained during production. All variables within the production process are identified, from feedstock consistency to moulding variations. With modelling, we can streamline the supply chain and scale faster. And for most of you, time-to-market matters most.

Eliminate scalability setbacks with OptiMIM

We have seen several medical manufacturers fall into the trap of using a "shortcut" manufacturing process, such as machining from bar stock, to validate their prototype and get to market as quickly as possible. While these processes may create a functional prototype, they are not scalable over the life of the programme. When these medical manufacturers move to a new process to scale for mass production, they must start process validation again from scratch, setting them back several months. In addition, different processes for the prototype and final component may require different design considerations, depending on the capabilities of each process.

With OptiMIM, we can produce fully functional prototypes to validate your design in a manner that remains scalable throughout the product life cycle. Rather than having to pivot from another process and undergo revalidation and potential redesigns, OptiMIM engineers can help guide your programme from conception through to mass production, enabling you to benefit from the full range of benefits of the MIM process. The earlier we are involved, the more value we can engineer into your component.

What benefits does automation add to the project?

Other manufacturing techniques, such as machining, can produce intricate geometries, but when it comes to scaling, metal injection moulding comes out on top. With a fully automated process, you can scale from low volume to high volume very quickly and without significant overhead. By implementing automation in your production process, you increase production times, reduce material scrap and achieve better product quality and repeatability with shorter lead times, so you receive your orders faster.

Can you give an example of automated process controls?

For example, one of our automated processes, Pressure Sensor Cavity Monitoring (PSCM), enables increased part complexity, stabilised process controls and increased mould cavitation. We can then increase annual part quantities and capacity while maintaining strict control and easing the transition to mass production. The PSCM system enables us to make real-time fine moulding adjustments, which is extremely important for consistency with sustained part process capability.  Without this system, we could see greater part-to-part tolerance variation. The PSCM system also keeps machines running more stably and for longer periods of time.

How do I lower the cost of scaling with MIM?

When deciding whether MIM is the right process for a project, it is important to assess scalability in relation to other technologies. It is also important to consider part complexity and the period over which the product will need to be produced in order to determine the most cost-effective method.

For example, choosing machining for a component that requires multiple set-ups and must be produced over a three- to five-year period could be costly due to the machine time required to complete the order. A machining centre also has limited capacity, potentially leading to additional costs later for extra machines or multiple suppliers—adding unnecessary risk to the supply chain.

One of the distinct benefits of MIM is scaling with the same footprint used for prototyping, thereby adding ROI over the life of the project. With MIM, cavitation can be added to existing moulding machines rather than adding more moulding machines to the process—meaning a lower investment cost for moderate to high volumes.

Final thoughts on scalability

Scaling does not mean that you have to produce millions of pieces a year. Scaling simply means having strong control of the process as you move towards full-scale production. The key is to maintain product and process controls without degrading capability. If you think your part could benefit from the MIM process, contact one of our design engineers who can explain the benefits in relation to your project.