<p>Support your automotive designs with OptiMIM’s precision-engineered metal components, combining metal injection moulding expertise with the most demanding standards.</p>

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Automotive

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MIM is ideal for producing intricate automotive parts, such as gears and engine components, that require precise tolerances and complex geometries.

Complex geometries

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MIM produces automotive parts with minimal machining requirements, reducing manufacturing time, costs, and waste. 

Near-net-shape

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MIM produces small, lightweight metal parts such as fuel injectors, sensors, and actuators, which contribute to improved fuel efficiency and reduced emissions in vehicles.

Compact solutions

MIM is well-suited for producing large quantities of identical automotive components for mass-market vehicles. 

High-volume production

Automotive leaders choose OptiMIM to help achieve key goals

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Industry-leading certifications

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<p>Manufacturers’ expectations are at an all-time high. Customers serve consumers who expect more—greater strength and density, more durable products and something unique—tailored specifically for them. How can a <a href="/metal-injection-molding/process" target="_self">metal injection moulding (MIM)</a> business keep pace?</p><p>How can the limited design freedom manufacturers faced in the past be addressed? It comes down to the foundation of the&nbsp;MIM process—feedstock. OptiMIM aims to manufacture using precisely the right blend of materials to create customised components that perform to the highest standards.  </p><p>Sources and related content</p><h2>What is feedstock?</h2><p>What exactly is feedstock? Fundamentally, it is a hybrid technology combining powder metallurgy and plastic injection moulding. Fine, spherical metal powder, almost resembling dust, is mixed with plastic and paraffin wax—or what we call the "binder" system. The binder system gives the part its shape according to the required geometry, while the metal powder remains incorporated.</p><p>The final feedstock is approximately 40% binder and 60% metal by volume, with powder particle sizes ranging from 10 to 25 microns. A micron is equal to one millionth of a metre, and for perspective, 40 microns is the smallest particle visible to the human eye. Did you know that the average human hair is 100 microns wide? All three materials are mixed together, extruded through our proprietary mixing system and pelletised.</p><p>The pellets are then fed into injection moulding machines and formed into the first stage of the part—the "green part". Many other downstream processes produce the final net-shape part, but feedstock is the foundation.</p><h3>Feedstock process control</h3><p>Custom-formulating alloys adds a layer of complexity to the process. It is critical for suppliers to maintain a sound, uniform and repeatable feedstock mixture for optimal consistency in mechanical performance and properties. Metallurgists’ knowledge and expertise must be precise, with very tight controls in place when incorporating multiple materials into the feedstock. Consistent dimensional control is needed not only from part to part, but also from batch to batch. This enables OptiMIM to achieve predictable and repeatable component shrinkage during the sintering phase every time.</p><p>With an emphasis on consistent dimensional control, you can devote the time and investment needed to fully optimise your design for performance without the traditional constraints associated with other processes.</p><h2>Design freedom with metal injection moulding</h2><p>Product performance is paramount. Customisation of MIM feedstock enables the design of technology and final parts that cannot be delivered by any other means.&nbsp;Instead of simply selecting a material to fit a part, the ideal combination should be created for optimal performance.</p><p>With the ability to produce its own feedstock, OptiMIM solves many complex design challenges. The combination of plastic injection moulding and powder metallurgy gives <a href="/additional-capabilities/engineering" target="_self">design engineers</a> freedom from the traditional constraints of shaping stainless steel, nickel iron, copper, titanium and other metals. Unlike other suppliers, engineers are not limited to an off-the-shelf metal that compromises project performance requirements.</p><p>Using the wrong materials in any process can affect part performance. That is why <a href="/materials/metal-selector-tool" target="_self">selecting specific material characteristics</a> with a finer degree of adjustment delivers better part performance. The proprietary combination of metal, wax and plastic polymers, together with other process controls, enables us to deliver tighter tolerances, high densities and smooth finishes compared with other forms of metal injection, while still producing precise, complex parts in large quantities. Because OptiMIM controls all variables in feedstock development as well as production processes, we deliver greater tolerance control from part to part and batch to batch with higher capability. This vertical integration gives us a unique advantage in the MIM industry.</p><h2>Designing metal parts for performance</h2><p>Design engineers can approach the MIM process without conventional design constraints. MIM creates component geometry by placing material only where it is needed for function and strength. Multiple components can be combined into a single MIM component, and the resulting geometry is stronger, more cost-effective and usually closer to the original design intent than assembling multiple parts. By consolidating components, risk is mitigated through reduced potential for part failure.</p><p>As all features are engineered into the tooling, part complexity does not drive cost. Conventional design methods, such as deburring or chamfering a stamped part, often result in a higher part price when complexity is added.</p><p>MIM excels where complexity, precision, quantity and performance intersect, and it all begins with custom-formulated feedstock. The material selected must deliver high-performing parts, regardless of component complexity.</p>

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Explore how tailoring material properties in MIM unlocks new possibilities for miniaturisation, weight reduction, and the formation of complex geometries in production.

Customising materials for greater design freedom | OptiMIM

Customised feedstock in Metal Injection Molding (MIM) provides greater design freedom, tighter tolerances and optimal performance by combining the benefits of plastic injection moulding and powder metallurgy. 

Customising MIM materials for greater design freedom

<p>Manufacturing is complex; small metal components can present a challenge to engineers who are limited in terms of their part’s material density, design flexibility and wall thickness. 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 most suitable 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 metal 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 suitable 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>What materials are used in metal injection moulding?</h2><p>MIM materials have had their chemistries modified to withstand the complex metal injection moulding process. There is 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 speciality 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 parting line 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 parting line location 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 are the minimum and maximum wall thicknesses that metal injection moulding can achieve?</h3><p>Wall thickness depends on the wall length, overall part size and part design. If the wall is localised, wall thicknesses as precise as 0.01” or less are possible. At the other end of the spectrum, wall thicknesses as large as 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 account 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 advantages in OptiMIM’s metal injection moulding FAQ resource guide.

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

<p>Both investment casting and metal injection moulding produce strong, precise metal components, but key differences can make one process better suited for 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 to 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>

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Compare investment casting and MIM for complex metal parts, highlighting differences in tolerances, costs, materials, surface finishes and production scale.

Investment casting vs. metal injection moulding

This webinar compares 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. 

Automotive

Automotive leaders choose OptiMIM to help achieve key goals

Complex geometries

Near-net-shape

Compact solutions

High-volume production

A look at
automotive applications

Industry-leading certifications

Beyond the basics

Expand your knowledge of metal injection moulding for automotive applications

Article

Article

Webinar

Global locations, customised solutions

Interested in starting your MIM project?

Automotive

Automotive leaders choose OptiMIM to help achieve key goals

Complex geometries

Near-net-shape

Compact solutions

High-volume production

A look atautomotive applications

Industry-leading certifications

Beyond the basics

Expand your knowledge of metal injection moulding for automotive applications

Article

Article

Webinar

Global locations, customised solutions

Interested in starting your MIM project?

A look at
automotive applications