What makes a good fit for MIM

With the abundance of metalworking solutions available, engineers frequently enquire about MIM (Metal Injection Moulding) and its ideal applications. MIM combines thermoplastic injection moulding and powder metallurgy to create intricate, dense, high-performing metal components. However, the key question is when MIM delivers the highest ROI compared with other processes for a specific project.

The suitability of a part for MIM is primarily determined by factors such as size, weight and volume. Overly large parts consume excessive space in MIM moulds, affecting cost-effectiveness. Nonetheless, part complexity often determines the potential ROI manufacturers can achieve with MIM.

Part sizes for metal injection moulding

The limiting factors for the metal injection moulding process are determined by the mould's size capacity and the amount of raw material required per component. For these reasons, MIM components are typically smaller than the palm of an average hand and weigh under 60 grams.

Metal injection moulding feedstock cost

MIM feedstock is a combination of very fine, customisable metal powders and polymers, which tends to be more expensive than typical molten casting alloys. As a result, material cost is one of the biggest limiting factors in the MIM decision-making process. At OptiMIM, our engineering team can help optimise your component's features to minimise wall thickness for the most ergonomic design.

Mould space and materials limit most MIM components to less than 3 inches in length, but what the MIM process lacks in size capacity, it more than makes up for in part complexity, repeatability and scalability.

Take advantage of increased complexity for maximum ROI

While MIM tooling has a higher initial cost than competitors that machine wrought stock, machine investment castings and machine conventional permanent mouldings, MIM part cost remains constant with additional complexity and moulded features.

MIM can achieve intricate features such as dovetails, slots, undercuts, fins, internal and external threads, or complex curved surfaces—just to name a few. MIM can also produce cylindrical parts with unique geometries and greater length-to-diameter ratios than most other casting technologies, as well as consolidate several components into one for better functionality.