Utilising MIM for Manufacturing at Scale

Producing a high-quality part with a short production time and 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 support scalability through automation, large batch capacity and relatively low upfront investment, but our engineers are also experts in streamlining your supply chain and validation processes.  

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

Why is manufacturing at scale important?

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 increase 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 where suppliers can fall short in delivering a quality component, 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 becomes key to success. The process should be less about getting parts to a customer as quickly as possible and more about establishing control across the process while reducing lead times over time. Emphasising the documentation of procedures and training prevents the loss of knowledge relating to key steps and controls when production increases. Manufacturers must be able to pivot and adapt to unexpected circumstances, 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 help ensure volume increases are achieved effectively and efficiently. Tolerances and dimensions are analysed to produce the degree 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. For most customers, 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 reach the 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, using 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 way that is scalable throughout the product life cycle. Rather than having to shift from another process and undergo revalidation and potential redesigns, OptiMIM engineers can help guide your programme from conception 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 metal injection moulding is superior when it comes to scaling. 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 rates, reduce material scrap, and achieve better product quality and repeatability with shorter lead times, allowing you to 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 quantity and capacity while maintaining strict control and easing the transition to mass production. The PSCM system allows us to make real-time fine moulding adjustments, which is extremely important for consistency and 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.

How do I lower the cost of scaling with MIM?

When determining whether MIM is the right process for a project, it is important to assess scalability relative 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 setups and must be produced over a three to five-year period could be costly due to the machine time needed 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 the ability to scale using 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, resulting in lower investment costs for moderate to high volumes.

Final thoughts on scalability

Scaling does not mean producing millions of pieces a year. It means maintaining strong process control while moving towards full-scale production. The key is to maintain product and process controls without capability degradation. If you believe your part could benefit from the MIM process, contact one of our design engineers, who can explain the benefits in relation to your project.