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OptiMIM - Resources - L1

Explore Metal Injection Molding (MIM), a technique for creating high-precision, complex metal parts. MIM combines metal powder with binders, molds them like plastic, then removes the binders to achieve near net-shape parts with excellent strength and density. Learn more about MIM's capabilities at OptiMIM's website.

Metal Injection Molding Overview

Metal Injection Molding (MIM) combines plastic injection molding and powdered metallurgy, offering greater design flexibility for shaping metals like stainless steel, titanium, and copper. The process begins with creating a feedstock of fine metal powders mixed with thermoplastic and wax binders, which is then injected into a mold to form a "green" part. After debinding to remove the binders, the part undergoes sintering at high temperatures to achieve its final strength and geometry, resulting in highly precise, complex components with reduced production costs.

Metal Injection Molding Process

OptiMIM is a Metal Injection Molding technology that creates high-performing, precision metal components. The MIM process allows for complex designs that can be produced with a focus on custom alloys and part consistency.

Introduction to OptiMIM

Metal injection molding is a process that merges two established technologies: plastic injection molding and powdered metallurgy. It offers a manufacturing capability of producing precise, complex parts in large quantities. MIM offers greater design freedom than many other production processes by freeing designers from the traditional constraints associated with trying to shape stainless steel, nickel iron, copper, titanium, and other metals.

Benefits of Metal Injection Molding

<h1>The MIM Performance Dividend</h1><p><strong></strong></p><p>It's time for design engineers to rethink metalworking processes that fail to deliver the necessary performance for their cost. MIM offers a solution. Download the mini-guide and discover 5 ways converting a part to MIM will exceed performance expectations.</p><p></p><p>From the guide:</p><p>“Designing more complex geometries into a part is often a necessary and innovative way to solve a problem. But it can’t come at the cost of lowered performance. After all, precision is non-negotiable.”  </p><h3>Download your copy to get the full story.</h3>

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This free mini-guide explores how metal injection molding (MIM) enhances part performance, enables complex geometries, and improves cost-effectiveness. 


The MIM Performance Dividend 

Download this free mini-guide to discover how converting parts to metal injection molding (MIM) can enhance performance, achieve complex geometries, and improve cost-effectiveness. 

The MIM Performance Dividend

<h1>MIM Design Guide</h1><h2>Get your free copy of our MIM Design Guide</h2><p>Imagine a complete palette of design freedom.</p><p>Learn about metal injection molding (MIM), and discover freedom from the traditional constraints of trying to mold stainless steel, nickel iron, copper, titanium, and other metals in part designs.</p><h3>DOWNLOAD NOW</h3><p>Get a free copy of the 66-page MIM Design Guide. Simply enter details below.</p><p>Download a free copy of the MIM Design Guide to learn:</p><ul><li>The characteristics of the ideal candidates for MIM</li><li>How complexity and cost stack up vs machined parts</li><li>Which limitations of traditional metalworking can be avoided</li><li>The “clean slate” approach to MIM design</li></ul><p><em></em></p>

Tired of design constraints with traditional metalworking? Explore the possibilities of MIM. Download the free guide and discover how to achieve complex designs with metals like stainless steel and titanium. 

MIM Design Guide 

Download our free 66-page MIM Design Guide to discover the design freedom of metal injection molding and learn how to overcome traditional metalworking limitations with your part designs. 

MIM Design Guide

<h1>Machining to MIM for Precision &amp; Cost Savings</h1><p>Spinal procedures are inherently complex, demanding precise placement of surgical instruments and exceptional dexterity.</p><p>Even when complications are avoided, traditional methods often necessitate forceful physical manipulation, leading to extended and painful recovery periods for patients.</p><p>Spine Wave, Inc., a Connecticut-based medical device company founded in 2001, addresses this challenge by developing surgical solutions specifically for spine treatments.</p><h3>Facilitating Easier Procedures</h3><p>Among their innovations is the Velocity® Expandable Interbody Device, which utilizes their groundbreaking expandable implant technology. This involves a small spacer inserted into the spine that expands once in place.</p><p>Velocity® is deployed using a handheld gun loaded with a cartridge containing the implant. Surgeons activate the trigger to insert the contents into the surgical site and can load multiple cartridges per procedure, seamlessly completing several implant expansions within a single surgery.</p><p>However, Spine Wave Manufacturing Engineer Zachary Sniffen and Senior Quality Engineer John Kapp emphasize the critical importance of ensuring that all steps leading up to implantation proceed just as smoothly.</p><p><em>Spine Wave is an innovator in surgical technologies for spinal implantation. But getting one of their next-generation instruments smoothly into surgeon’s hands and safely into surgery was costly, and required extra caution during shipment.</em></p><p><em>Their engineers turned to OptiMIM to deliver a more cost-effective solution—and make delivery smoother, right out of the box.</em></p><p>Readying the Velocity® Expandable Interbody Device for surgery involves accessing cartridges from their sterile packaging, and snapping them onto the gun. “Surgeons could have trouble mating the gun to the cartridge in the moment if the components within the cartridge become misaligned during shipping,” Sniffen says.</p><p>Spine Wave needed to lock the components inside the cartridges during shipping in a way that allowed a uniform, predictable, and automatic disengagement of the lock when loaded onto the gun. And the shipping lock was born.</p><p>The shipping lock, a compact, clip-like piece with posts extending from the body, holds components in place during transport. The gun pushes the lock out of the way during loading, ensuring the entire process is smooth and uninterrupted.</p><p>The shipping lock’s design was effective, but because they were machined from raw bar stock, that reliability came at a high cost, says Kapp. “We had to change processes, and we knew metal injection molding would give us a cost reduction.” That’s when they contacted OptiMIM.</p><h3>Facilitating Easier Procedures</h3><p>“Complex geometries and intricately shaped features make medical devices a great fit for the MIM process,” says OptiMIM. “Spine Wave could have spent 6 or 7 times more on machining this part than they would on MIM.”</p><p>OptiMIM worked with the engineering team to get them the best cost, a major consideration for Spine Wave. But ultimately, says Sniffen, it came down to OptiMIM’s capabilities.</p><p>“We saw the best opportunity for a quality part from OptiMIM, and their willingness to work with us on our design intent,” he says. “We had fairly tight tolerances for some features, and we saw that the engineers at OptiMIM would work through those potential speed bumps to get the best part possible.”</p><p>Spine Wave determined that with OptiMIM’s capacity for ultra-high volumes, cost-efficiency would be maximized by extending the shipping lock application to a second product. “After going through the numbers, we saw it would pay for itself fairly quickly,” says Sniffen. “It was pretty much a no brainer for us.”</p><h3>The OptiMIM Decision</h3><p>“With projecting features like the shipping lock posts, the injection molding process always presents challenges, with cooling and flexing and bowing,” says Kapp. So during development, the Spine Wave engineers engaged in OptiMIM’s design for manufacturing (DFM) methodology to optimize manufacturability—and additionally visited OptiMIM’s Portland, Oregon facility to collaborate directly with the MIM experts.</p><p>During these interactions, the Spine Wave engineers discovered OptiMIM’s 100 years of in-house MIM experience—or rediscovered it, in Kapp’s case. It turns out he’d worked with OptiMIM years ago under its original name, Kinetics. “They’ve done some very technically challenging work. It was the right choice for this project,” he says.</p><p>“We met our target dates, we got a cost reduction which makes everyone happy, and we transitioned from the old part without hiccups,” says Kapp. “For a quality engineer, having nothing to report is a resounding endorsement.”</p><p><em>“The engineers at OptiMIM had the foresight to see a potential issue on a susceptible part that didn’t appear during development. Because of their expertise, we were able to circumvent the issue and avoid any inventory delays.”</em></p>

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Learn how Spine Wave partnered with OptiMIM to leverage metal injection molding for a complex shipping lock, reducing costs and improving safety for their Velocity® Expandable Interbody Device. 

Machining to MIM for Precision & Cost Savings 

To reduce costs and improve the safety of their Velocity® Expandable Interbody Device, Spine Wave partnered with OptiMIM to manufacture a complex shipping lock component using metal injection molding, resulting in a more cost-effective and reliable solution. 

Machining to MIM for Precision & Cost Savings

<h1>Molding Excellence With MIM Specialty Alloys</h1><p>Interested in manufacturing parts with complex geometries that have the strength and durability of metal? Metal Injection Molding (MIM) with specialty alloys allows for greater manufacturing possibilities in industries such as automotive, aerospace, medical, electronics, and more.</p><p>Join an informative webinar on OptiMIM's specialty alloys, utilizing the metal injection molding (MIM) process. Discover how MIM seamlessly combines plastic injection molding with the strength of metals, offering unparalleled design flexibility and scalability.  </p><p>Sources and related content</p><p>In this webinar, gain insights in: </p><ul><li>Optimim's range of specialty alloys</li><li>Learn about Kovar, Copper, Nitronic 60, Nickel Iron, Silicon Iron, S7</li><li>See how complex geometries are produced by utilizing MIM</li><li>MIM’s cost effectiveness with optimized material usage</li><li>See Scalability with MIM, from prototypes to high-volume production</li><li>And more!</li></ul><p><strong>Molding Excellence With MIM Specialty Alloys</strong><br /><strong>When</strong>: On-Demand<br /></p><h3>Fill out the form to sign up for our free on-demand webinar:</h3>

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Learn how Metal Injection Molding (MIM) with specialty alloys enables complex geometries, high strength, and cost-effective production. 

Molding Excellence With MIM Specialty Alloys 

David Fuerst

Sr. Project Manager

Steve LeBlanc

Engineering Manager

This webinar explores the advantages of Metal Injection Molding (MIM) with specialty alloys, showcasing its ability to produce complex, durable, and cost-effective metal parts for various industries. 

Molding Excellence With MIM Specialty Alloys

<h1>MIM Round Table</h1><h2>Join OptiMIM Engineers, John Gaspervich and John O’Donnell, for a unique round-table discussion on metal injection molding.</h2><p><strong>Download the on-demand webinar by filling out the form below.</strong></p><p>Watch the previously recorded webinar to learn about OptiMIM's (formerly Dynacast) grand prize-winning Canard “missile fin” components and their strict material requirements as well as innovations in the industry. Unique to this round-table, attendees had the opportunity to ask questions to two of OptiMIM’s top experts on design for manufacturing, quality review practices, manufacturing process control, and new product development. Hear their questions and answers!</p><h3>Fill out the form to sign up for our free on-demand webinar:</h3>

This on-demand webinar covers design, quality control, and new product development, featuring a case study on award-winning Canard "missile fin" components. 

MIM Round Table 

This on-demand webinar features a round-table discussion with OptiMIM engineers on metal injection molding, covering topics like design for manufacturing, quality control, and new product development, and showcasing their award-winning Canard "missile fin" components. 

MIM Round Table

<h1>Securing Scalability: Utilizing MIM to manufacture at scale</h1><h2>Streamline regulatory design validation and manufacture at scale with metal injection molding</h2><p>When a component first goes into production, the top priority is manufacturing a sound, high-performing part—many processes can achieve that. But over the life of a project, effectively scaling the production process at the lowest total cost becomes increasingly critical. For manufacturing small, complex components at scale, metal injection molding (MIM) is the most efficient process.</p><p>OptiMIM has experts in taking projects all the way from the drawing board into mass production. Not only does the metal injection molding process lend itself to scalability with automation, large batch capacity, and relatively low up-front investment, but</p><p>engineers are experts in streamlining supply chains and validation processes.  </p><p>Sign up for a free on-demand webinar and learn how to take advantage of the MIM process to efficiently manufacture components from the prototyping stage all the way through mass production. The webinar covers:</p><ul><li>Streamlining regulatory validations, like FDA approval</li><li>Manufacturing with MIM at a lower total cost to scale</li><li>Shortening your supply chain with automation and part consolidation</li><li>MIM case studies</li></ul><h3>Fill out the form to sign up for our free on-demand webinar:</h3><p></p><p>Don’t just take our word for it. This year, OptiMIM was recognized by the Metal Powder Industries Federation (MPIF) at the 2020 Powder Metallurgy Design Excellence Awards for the design and production of one of two jaws of a surgical device for the Medical/Dental Category. This part ran at approximately 10,000 parts per year, and was recognized for excellence in precision and durability.</p><p><strong>With OptiMIM, producing high-performing parts at scale is standard.</strong></p>

Learn about metal injection molding (MIM) for scalable manufacturing. This webinar covers cost optimization, FDA approvals, supply chain efficiency, and MIM case studies. 

Securing Scalability: Utilizing MIM to manufacture at scale 

Learn how to scale production of small, complex components efficiently and affordably using metal injection molding (MIM) in this free on-demand webinar. 

Securing Scalability: Utilizing MIM to manufacture at scale

<h1>What's a Good Fit for MIM?</h1><h2>Is Metal Injection Molding Right for Your Project?</h2><p>With numerous metalworking solutions available, engineers often ask, "What is MIM and when is it the right choice?"</p><p>Past Metal Solutions Webinars have covered&nbsp;MIM materials, the&nbsp;MIM process, and&nbsp;how to leverage MIM technology for higher-performance components. It's already been established that MIM combines the technologies of thermoplastic injection molding and powder metallurgy to produce complex shaped, high density, high-performance metal parts. But when does MIM deliver the most ROI compared to other processes?  </p><p><strong>Sign up for the on-demand webinar, What’s a Good Fit for MIM</strong>, to discover the characteristics that make a component a good candidate for the MIM process. The webinar covers:</p><ul><li>MIM design capabilities and part criteria</li><li>Getting the most value from the MIM process</li><li>Where MIM saves cost</li><li>And more!</li></ul><h3>Fill out the form below to sign up.</h3>

Explore MIM's design capabilities, cost-saving potential, and ideal applications. 

What's a Good Fit for MIM? 

This on-demand webinar explores when to choose Metal Injection Molding (MIM) over other metalworking solutions, covering MIM's design capabilities, cost-saving potential, and optimal applications. 

What's a Good Fit for MIM?

<h1>Shaping the Future: Part Consolidation with MIM</h1><p>The key to streamlining a supply chain is eliminating risk and minimizing the number of suppliers needed to manufacture a product. Ideally, assembly costs are also reduced. Utilizing the metal injection molding process to single source complex components achieves both.</p><p>The metal injection molding process lends itself to complex components and part consolidation that cannot be achieved by any other single process. Sign up for</p><p>the next webinar and discover how customers develop custom materials and solutions by understanding their pain points, as well as:  </p><ul><li>Methods of part consolidation</li><li>How to eliminate secondary assemblies</li><li>Risk mitigation</li><li>Complex component case studies</li></ul><h2>Fill out the form to access the recording.</h2>

Streamline your supply chain with metal injection molding (MIM). Consolidate complex parts, reduce suppliers, and eliminate secondary assemblies. Learn how MIM can improve your manufacturing process. 

Shaping the Future: Part Consolidation with MIM 

Metal injection molding (MIM) streamlines your supply chain by consolidating complex parts, reducing suppliers, and eliminating secondary assemblies. 

Shaping the Future: Part Consolidation with MIM

<h1>MIM Experts Panel: FAQ</h1><p><strong>Burning questions about MIM technology? We’ve got the answers.</strong></p><p>In some of our recent Metal Solutions webinars, we’ve covered several niche topics, including using <strong>MIM materials</strong> to solve manufacturing problems, <strong>achieving scalability</strong> throughout your production process, and the possibilities of <strong>part consolidation</strong> with MIM technology. Over the course of these webinars, we get similar questions about our technology each time—so, we think it’s time to get back to the basics. <strong>But this time, we’re going to switch it up.</strong></p><p><strong>Join us in this on-demand webinar </strong>to take part in a new webinar format centered around you—the customer—and commonly asked questions. For this webinar, we’ve gathered a panel of metal injection molding experts to answer your frequently asked questions on the following topics:</p><ul><li>The MIM process</li><li>MIM materials</li><li>Design considerations</li><li>Part consolidation</li><li>Process comparisons and conversions</li><li>And production volume</li></ul><p>If you’re new to the MIM process or you need a refresher on our technology’s capabilities, this webinar is for you.</p><h2>Fill out the form to sign up and access the on-demand webinar.</h2>

Get answers to common questions about the MIM process, applications, and benefits. Sign up on-demand for free! 

MIM Experts Panel: FAQ 

This on-demand webinar offers a new format where metal injection molding (MIM) experts answer frequently asked questions about the MIM process, materials, design considerations, part consolidation, process comparisons, and production volume. 

MIM Experts Panel: FAQ

<h1>MIM Materials</h1><p>MIM 101 and MIM Design have been covered. Next, learn more about the materials used in metal injection molding. Discover different material options and the science behind modifying custom alloys to enhance the complex metal injection molding process. Explore case studies highlighting custom material solutions delivered to customers for a competitive advantage.</p><p>Sign up below for your free on-demand download!</p><h2>Sign up for this free webinar!</h2>

Optimize your metal injection molding with the right materials. Learn about custom alloys and gain a competitive edge. Register for this free webinar. 

MIM Materials 

This webinar delves into the materials used in metal injection molding, exploring different options and the science of modifying custom alloys to enhance the MIM process, featuring case studies showcasing the benefits of unique material solutions. 

MIM Materials

<h1>Investment Casting vs. Metal Injection Molding: A process comparison</h1><p>Both investment casting and metal injection molding produce strong, precise metal components, but key differences can make one process better suited for specific applications.</p><p>Metal injection molding (MIM) 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>Medical/dental case studies</li><li>Aerospace/defense applications</li><li>Production volumes</li><li>Surface finishes</li></ul><p><em>** For best experience, please register and attend the webinar on one of our supported browsers: Google Chrome, Safari, or Firefox. **</em></p><h2>Fill out the form to sign up for this free webinar!</h2>

Learn from industry experts about tolerances, case studies in medical/dental and aerospace/defense fields, production volumes, surface finishes, and more. 

Investment Casting vs. Metal Injection Molding: A process comparison 

This webinar compares and contrasts investment casting and metal injection molding, examining material options, tolerances, and applications in the medical/dental and aerospace/defense industries, with case studies and a discussion of volumes and surface finishes. 

Investment Casting vs. Metal Injection Molding: A process comparison

<h1>How to Solve Problems with MIM Materials</h1><p>At OptiMIM, a key differentiator is the customizable feedstock, produced in-house. This feedstock is made by combining very fine metal powders with thermoplastic and wax binders in a precise recipe to achieve between 95 and 100% theoretical density and close tolerances over high-production runs.</p><p>Making MIM materials to achieve higher strength and density sounds great on paper—but that doesn’t even begin to cover all of the problems that can be solved with</p><p>proprietary feedstock capabilities.</p><p>In this webinar, MetalSolutions series veteran John O’Donnell and OptiMIM Engineering and Tooling Manager Steve LeBlanc will cover the many ways MIM materials can solve common manufacturing problems, including:</p><ul><li>Modifying material to suit project requirements</li><li>Creating custom material to suit project requirements</li><li>Achieving higher strength, density, and durability than with powder metallurgy</li><li>Shortening your supply chain</li><li>Greater design freedom,  and more!</li></ul><p><em>** For best experience, please register and attend the webinar on one of our supported browsers: Google Chrome, Safari, or Firefox. **</em></p><h2>Please fill out the form to download our free on demand webinar.</h2>

Learn how custom MIM materials can solve your manufacturing challenges. Achieve higher strength, tailored properties, and shorter supply chains. 

How to Solve Problems with MIM Materials 

This webinar explores how customizable metal injection molding (MIM) materials can solve manufacturing challenges by enabling higher strength, tailored properties, shorter supply chains, and greater design freedom. 

How to Solve Problems with MIM Materials

<h1>Leveraging MIM for Performance</h1><p>In production, high costs often stem from secondary operations and manual assembly. Each additional step increases expenses and the potential for inconsistencies.</p><p>Metal injection molding (MIM) nearly eliminates the need for these extra steps.</p><p>MIM technology delivers consistently high-quality, complex metal components at scale. It optimizes part performance and reduces secondary operations. With best-in-class controls, value-engineered part consolidation, and strength and density across a wide range of alloys, MIM offers a way to optimize precision components and produce them in virtually any volume. Expert design for manufacturing knowledge is applied to each project.</p><p><strong>Webinar Topics:</strong></p><ul><li>MIM technology innovations and processes</li><li>MIM design for manufacturing engineering</li><li>Part consolidation</li><li>MIM performance benefits</li></ul><h2>Fill out the form to access the recording.</h2>

Discover the process, capabilities, applications, and how MIM compares to other metalworking solutions. Register to watch now. 

Leveraging MIM for Performance 

Metal injection molding (MIM) eliminates secondary operations and manual assembly to deliver high-quality, complex metal components at scale with optimized performance. 

Leveraging MIM for Performance

<h1>MIM Overview</h1><p>With numerous metalworking solutions available, it's easy to become complacent. But what if a better option exists? Metal Injection Molding (MIM) combines the technologies of thermoplastic injection molding and powder metallurgy to produce complex shaped, high density,</p><p>high-performance metal parts. Learn more by downloading our on-demand webinar.</p><p>Get insight on:</p><ul><li>The MIM process</li><li>Capabilities and applications of MIM</li><li>How MIM competes in the metals industry</li></ul><h2>Fill out the form to access the recording.</h2>

MIM Overview 

This webinar provides an overvew of Metal Injection Molding (MIM), an advanced manufacturing process that combines the This webinar provides an introduction to Metal Injection Molding (This This webinar provides an introduction to Metal Injection Molding (MIM), an innovative process combining thermoplastic injection molding and powder metallurgy to produce complex, high-performance metal parts. 

MIM Overview

<h1>MIM 101</h1><p>Metal Injection Molding (MIM) is a revolutionary technology that combines the versatility of plastic injection molding with the strength of metal. This advanced manufacturing process is transforming the way precision metal components are produced.</p><h2>Why Metal Injection Molding?</h2><p>Metal Injection Molding is at the forefront of cutting-edge technology, enabling the cost-effective production of complex, high-quality metal parts. By merging the design flexibility of plastic injection molding with the strength and performance of metals, MIM opens a world of possibilities across industries such as automotive, aerospace, medical, electronics, and more. </p><h2>Benefits of Metal Injection Molding:</h2><ul><li>Complex Geometries: Unlock the potential for intricate part production. </li><li>Cost-Effective: Optimize material usage and reduce costs for enhanced affordability. </li><li>High Precision: Achieve tight tolerances and excellent finishes for consistent quality. </li><li>Wide Material Selection: Harness a variety of materials, including stainless steel, titanium, copper, and more. </li><li>Scalability: Seamlessly transition from prototypes to high-volume production. </li></ul><p>To learn more, join us Tuesday, August 1 at 2 p.m. to uncover the potential of MIM </p><p>Register now for this webinar, Metal Injection Molding (MIM) 101, to gain a deeper understanding of how MIM can benefit your projects and revolutionize your manufacturing capabilities. </p><p><strong>Webinar Details: </strong></p><ul><li><strong>Metal Injection Molding (MIM) 101</strong></li><li><strong>When:</strong> On-Demand<br /></li></ul><p><strong>Fill out the form to access the recording. </strong></p>

Discover how MIM combines the benefits of plastic injection molding and metal to create complex parts cost-effectively. 

ME 101 

<h1>Customizing Materials for Greater Design Freedom</h1><p>Manufacturers’ expectations have hit an all-time high. Customers are serving consumers who want something more—better strength and density, more durable products, something unique—tailored just for them. How does a metal injection molding (MIM) business keep up with the times?</p><p>How is the limited design freedom that manufacturers faced in the past solved? It all boils down to the very foundation of the&nbsp;MIM process—feedstock. OptiMIM aims to manufacture with just the right blend of materials to create personalized components that perform to the highest standards.  </p><p>Sources and related content</p><h2>What is feedstock?</h2><p>Now, what exactly is feedstock? At the basis, it's the hybrid technology between powder metallurgy and plastic injection molding. A fine spherical, metal powder, almost resembling dust, is mixed with plastic and paraffin wax—or what we like to call the "binder" system. The intent of the binder system is to give the part its shape to your geometry, while the metal powder goes along for the ride.</p><p>The final feedstock is approximately 40% binder and 60% metal by volume, with the size of the powder particles ranging from 10 to 25 microns. A micron is equal to one millionth of a meter, and to put that in 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 from our proprietary mixing system, and pelletized.</p><p>The pellets, in turn, are fed into the injection molding machines, and formed into the first stage of the part – the "green part". Many other processes happen downstream to produce the final net-shaped part, but feedstock is the understructure.</p><h2>Feedstock process control</h2><p>Custom formulating alloys adds a layer of complexity to the process. It's critical for suppliers to have a sound, uniform, and repeatable mixture of feedstock for optimal consistency of mechanical performance and properties. The knowledge and expertise of the metallurgists must be precise, with very tight controls in place, when incorporating multiple materials in the feedstock. Consistent dimensional controls are needed not only from part to part, but from batch to batch. It is what allows OptiMIM to have predictable and repeatable shrinkage of our components during the sintering phase each and every time.</p><p>With an emphasis on consistent dimensional control, you are able to spend the time and investment needed to fully optimize your design for performance without the traditional restraints associated with other processes.</p><h2>Freedom to design your best</h2><p>Product performance is paramount. The customization of MIM feedstock allows for the design of technology and final parts that cannot be delivered by any other means.&nbsp;Instead of simply picking a material to fit a part, the perfect fusion should be created for optimal performance.</p><p>Read more about custom material options in the blog Material Options: How does MIM compare?</p><p>With the ability to produce its own feedstock, OptiMIM solves a lot of complex design problems. The combination of plastic injection molding and powdered metallurgy allows design engineers freedom from the traditional constraints of trying to shape stainless steel, nickel iron, copper, titanium, and other metals. And unlike other suppliers, engineers are not stuck with an off-the-shelf metal that compromises project performance requirements.</p><p>Using the wrong materials in any process can impact the part performance. That’s why selecting particular material characteristics with a tighter degree of fine-tuning, delivers better part performance. The proprietary combination of metal, wax, and plastic polymers, along with other process controls, allows us to deliver tighter tolerances, high densities and smooth finishes compared to other forms of metal injection, and while still producing precise, complex parts in large quantities. Since OptiMIM controls all variables of the feedstock development, as well as production processes, we deliver higher 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 parts for performance</h2><p>Design engineers can look at the MIM process as a clean slate. MIM builds component geometry by placing material only where it’s 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 is usually closer to the original design intent than assembling multiple parts. By consolidating components, risk is mitigated with less potential for part failure.</p><p>Since all features will be engineered into the tooling, part complexity will not drive cost. Conventional methods of designing, like deburring or chamfering on a stamped part, often equate to higher part price when adding complexity.</p><p>MIM dominates at the intersection of complexity, precision, quantity and performance, and it all begins with custom-formulated feedstock. The material you choose needs to deliver high-performing parts, no matter how complex the component.</p><p>Download the free white paper The MIM Performance Dividend to read more.</p>

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Overcome design limitations with customized MIM feedstock. 


Customizing Materials for Greater Design Freedom 

Customized feedstock in Metal Injection Molding (MIM) allows for greater design freedom, tighter tolerances, and optimal performance by combining the benefits of plastic injection molding and powdered metallurgy. 

Customizing Materials for Greater Design Freedom

<h1>Streamlining FDA Approval With OptiMIM</h1><p>Staying ahead of production roadblocks like FDA validation is essential to getting to market before your competition. <strong>Since FDA validation can take anywhere from six months to two years to get the product fully surveyed, approved, and into the marketplace, it’s important to choose a superior process that reduces risk, variance,  and part failure to make FDA approval easier.</strong></p><p>With OptiMIM’s value-added process, complex capabilities, and engineering expertise, you can reduce the need for secondary assembly, single-source your components, and streamline your supply chain to shorten your design and process validation processes. And you can do it all to scale.</p><h2>Working with FDA approval requirements in mind</h2><p>When considering manufacturing processes for your medical components, whether in the prototyping or mass production stage, you want to factor in FDA approval processes and requirements into your decision. The product must pass both process and design validation to guarantee its function and quality.</p><p>Section 820.3(z) of the Code of Federal Regulations Title 21 states that validation entails an “examination and provision of objective evidence that the particular requirements for a specific intended use can be consistently fulfilled,” presenting in both process and design validation.</p><p>During the course of approval, your chosen manufacturing process will be subject to scrutiny in process validation. You need a manufacturing process that is reliable, repeatable, and produces parts with guaranteed composition and geometries.</p><h2>OptiMIM process guarantee</h2><p>With our proprietary MIM process, custom feedstock, and enhanced strength and elongation capabilities, our process is built to make FDA approval smooth sailing. Since we make our feedstock in-house, we can guarantee its exact composition each time. And our proprietary furnace recipes make for higher strength and elongation properties in our components—especially components of stainless steel. With OptiMIM, our superior process means that you’re reducing risk, variance, and part failure, making it easier for the process to be validated by the FDA.</p><p>In addition to having an impact on the length of your process validation, your chosen manufacturing process and the supplier also have a potential impact on the length of your component’s design validation. With these high stakes, it’s important to choose a partner who helps to streamline FDA validation.</p><p><em>With OptiMIM, you can achieve complexity without compromise. </em></p><h2>Early supplier involvement to streamline design validation</h2><p>The MIM process is designed to produce extremely complex geometries, and you can achieve your net-shape component with minimal up-front investments as compared to other processes. With years of experience in the medical industry under our belt, OptiMIM knows the ins and outs of the design validation requirements for medical components. And with early supplier involvement, you can take advantage of our many combined years of engineering expertise to move your component quickly from concept to production with all of your desired part features—without supply chain hiccups.</p><p>Have you considered the benefits of part consolidation? Or thought it to be impossible with your current process? Not with OptiMIM. Our value engineering and greater design freedom means that you can reduce the need for secondary assembly, single-source your components, and streamline your supply chain to shorten your design validation process and get to market sooner than your competitors. And OptiMIM enables you to do it at scale.</p><p><strong>Interested in learning more about our part consolidation capabilities? Check out our blog post!</strong></p><h2>Eliminate scalability setbacks with OptiMIM</h2><p>We’ve seen several medical manufacturers stumbling into the trap of using a “shortcut” manufacturing process like machining from bar stock to validate their prototype and get to market as fast as possible. While these processes may create a functional prototype, they are not scalable over the life of the program. So when these medical manufacturers move to a new process to scale for mass production, they must start the process validation over again from scratch, setting them back several months. On top of that, different processes for prototype and final component might mean different design considerations, depending on the capabilities of each process.</p><p>With OptiMIM, we can produce fully functional prototypes to validate your design in a way that is scalable throughout the life of the product. Rather than having to pivot from another process and suffer the re-validation and potential re-designs, OptiMIM engineers can help guide your program all the way from conception to mass production so that you can take advantage of the full suite of benefits of the MIM process. The earlier we’re involved, the more value we can engineer into your component.</p><h2>Streamline FDA approval at scale</h2><p>If you’re looking for a supplier with experience in the medical industry and process and design validation for the FDA, look no further than OptiMIM. Contact our engineering team today to learn more about how OptiMIM can lend value to your medical component program.</p>

Need faster FDA approval for your medical device? OptiMIM's advanced metal injection molding process simplifies validation and ensures scalability. 

Streamlining FDA Approval With OptiMIM 

Choosing the right manufacturing process, like OptiMIM's metal injection molding, with its complex capabilities, early supplier involvement, and scalability, can significantly streamline FDA approval for medical devices. 

Streamlining FDA Approval With OptiMIM

<h1>Material Options - How Does MIM Compare?</h1><h2>Complexity demands precision</h2><p>When you think of the metal injection molding and powder metallurgy processes, a few key characteristics come to mind. These components are usually high in mechanical strength, highly dense, and perform well in corrosive environments. Because of the nature of the MIM process specifically, MIM components are exceptionally dense across the board.</p><p>But what sets the OptiMIM process apart from the rest? Far and away, our distinguishing factor is our custom feedstock and enhanced material performance. While many of our competitors import BASF feedstock to mold components, our OptiMIM metallurgists make specialized, made-to-order feedstock with compositions tailored to each project. Since we produce our own feedstock, we have full control of all the ingredients, the recipes, and especially the control of the variables so we can guarantee the precise composition and consistency of each component.</p><h2>Why does material composition matter?</h2><p>Made-to-order feedstock sounds great on paper. But how does the quality difference translate to part performance?</p><p>With MIM, custom feedstock and precise powder composition contribute to an enhanced grain structure and grain boundary condition. This adds up to reliable and repeatable capabilities, optimal part density, highest ultimate strength, and best elongation of all final MIM components.</p><p>Feedstock | Material Composition | Injection Molding</p><p>Since we manufacture our own feedstock, we have the freedom to specify the metal particle size distribution and develop the binder composition for each project. This makes OptiMIM’s process fully customizable to deliver the end mechanical performance and properties your application requires rather than having to settle for off-the-shelf properties of wrought metals.  Our technical experts are able to manipulate these elements to deliver on different performance requirements. This, partnered with our ability to optimize furnace recipes, ensures that OptiMIM parts are more structurally sound and consistent, perform more reliably, and are less prone to embrittlement (cracking) than parts produced with BASF feedstock. Since we can guarantee the structure and exact material composition of each part, we can guarantee industry-leading yield strength and other relevant mechanical properties.</p><h2>MIM Metals: A cut above the rest</h2><p>OptiMIM’s precise and uniquely engineered feedstock composition, along with our proprietary grain structure, allows us to deliver both high strength as well as the highest elongation (ductility) performance in the industry. With other processes, design engineers are often forced to decide between optimizing mechanical strength or optimizing elongation—with OptiMIM you can have both.</p><p>For example, with 17-4PH stainless steel, heat treated to H-900, the OptiMIM mechanical properties yield up to 19% better ultimate and yield strength and up to 125% higher elongation than the Metal Powder Industries Federation (MPIF Std 35) industry standards.</p><h2>What are my material options for metal injection molding?</h2><p>At OptiMIM, we specialize in various ferrous and non-ferrous alloys including several stainless steel grades, copper and copper alloys, and low alloy steel components which make up about 70% of our business. We also have experience processing specialty alloys like Cobalt-Chromium (F-75) and other high alloy materials. But that’s not all we do.</p><p>MIM materials can have their chemistries modified when utilized in the complex metal injection molding process. These materials are customizable and come in a wide variety, and they generally fall into four categories:</p><p>Ferrous alloys</p><p>Steels, stainless steels, tool steels, iron-nickel magnetic alloys, non-magnetic alloys and specialty alloys such as Invar and Kovar make up our ferrous alloy materials. Ferrous alloys are characteristically strong because they have an iron-based composition, and are often used in medical and automotive applications.</p><p>Tungsten alloys</p><p>Our tungsten alloys are characteristically high in tensile strength and are naturally resistant to corrosion. We often work with a tungsten-copper alloy for parts that require a material that is heat-resistant, ablation-resistant, and is highly thermally and electrically conductive.</p><p>Cemented carbide alloys</p><p>The MIM process is compatible with hard materials such as cemented carbides and cermets. These materials consist of hard and wear resistant carbide and a tough and ductile metal binder, thus delivering a unique combination of hardness and toughness.</p><p>Special material alloys</p><p>Specialty materials that we see a lot in the MIM process include, but are not limited to, precious metals, titanium alloys, cobalt-chromium, nickel, nickel-base super alloys, molybdenum, molybdenum-copper, and particulate composites.</p><p><strong>Learn more about available material options and applications for metal injection molding. Download the free webinar!</strong></p>

Discover how OptiMIM's unique metal injection molding process delivers superior strength, ductility, and consistency in custom metal components. Learn about material options and advantages. 


Material Options - How Does MIM Compare? 

OptiMIM's unique, customizable feedstock allows for greater control over material properties in metal injection molding, resulting in components with superior strength, ductility, and consistency compared to those made with standard feedstocks. 

Material Options - How Does MIM Compare?

<h1>Value-Added Part Consolidation with MIM</h1><h2>Complexity demands precision</h2><p>Designing more complex geometries into a part is often a necessary and innovative way to solve a problem. But it can’t come at the cost of lowered performance. After all, performance is non-negotiable. When you’re producing highly complex or intricate components, you need consistently reliable performance during production.</p><p>Choosing the wrong production methods for complex parts could add costly secondary processes—deburring or chamfering on a stamped part, for instance, or assembling two dissimilar parts for one product—and introduce additional variance.</p><p>In the production process, some of the highest cost-drivers are associated with secondary operations and manual assembly. At the end of the day, both of these processes require more hands and possibly more manufacturers, and each of these factors adds cost.</p><p>That’s where metal injection molding comes in. MIM makes it possible to integrate and consolidate several components into a single, net-shape molded piece—reducing the need to work with several manufacturers and decreasing processing and assembly costs. And MIM makes it all possible without compromising performance.</p><h2>Part consolidation</h2><p>Complexity demands precision, and it historically goes hand-in-hand with added cost. But with MIM, you can achieve the complexity you require without an automatic price increase. The cost of MIM parts remains largely constant no matter the complexity, which translate to a higher up-front cost in tooling that leads to savings down the line.</p><p><strong>With MIM, complexity isn’t an automatic price increase</strong></p><p>Typically, when designing a component with several disparate parts, cost is hidden in the secondary operations, a lengthened supply chain, and tooling maintenance. When several separate parts are tooled, the need for assembly introduces additional providers into the supply chain. When production processes are outsourced, the handoff generates greater possibility for part variance and defect. The additional stop in the supply chain also adds time, which delays deliverability to market.</p><p>In addition to requiring secondary assembly, each singular part would require its own mold cavity, which drives up cost both with the initial purchase of several molds and later when the tooling wears down and needs to be replaced.</p><h2>Consolidation and cost savings without compromising performance</h2><p>While the decision to consolidate parts introduces an array of benefits, it can mean greater complexity, too. And that’s where design engineers traditionally have to weigh the trade-offs: on one hand, part consolidation has the potential to save weight, costs, and time; increase strength and performance; and even compress the supply chain. On the other, when using materials and processes that mismatch critical factors such as thermal expansion, joints, and adhesives, the resulting part could be compromised.</p><p>It doesn’t have to be this way. When parts are consolidated with MIM, the component is stronger and more cost-effective. In fact, it’s produced even closer to the original design intent than the assembly.</p><p><strong> When parts are consolidated with MIM, the component is stronger and more cost effective.</strong></p><p> MIM can incorporate many traditionally machined features into one net-shape molded part from one single mold cavity. Features may include internal and external threads, intersecting diameters, knurling, and customer-unique branding—all with the ability to scale economically as demand for your product increases. And since MIM can successfully consolidate into one molded part, each part can be sourced completely in-house.</p><p><em>While MIM tooling has a higher initial ticket price than our competitors who machine wrought stock, machine investment casting, and machine conventional permanent molding, MIM part cost remains constant with additional complexity and molded features.</em></p><p>This means traditional design limitations are lifted, and the number of parts that have to be purchased, tracked, and managed through inventory are reduced—and so are the trade-offs.</p><p>What we’re saying is that MIM adds value across your entire supply chain. You won’t just see ROI on the part itself, but throughout the whole value stream. With increased speed-to-market, guaranteed precision, and high-performing parts, you’ll see the benefits of MIM from start to finish of your production process.</p>

Consolidate multiple parts into a single, complex component without compromising quality. 

Value-Added Part Consolidation with MIM 

Metal injection molding (MIM) allows for the consolidation of multiple parts into a single, complex component, reducing costs and improving performance without the compromises often associated with traditional assembly methods. 

Value-Added Part Consolidation with MIM

<h1>Metal Injection Molding FAQ</h1><p>Manufacturing complex, small metal components can present a challenge to engineers who are limited in scope in terms of their part’s material density, design flexibility, and wall thickness. If you are looking for high quality, complex, precision metal components less than 160 grams, then OptiMIM’s metal injection molding process may be the best course of action.</p><p>Metal injection molding, or MIM, is a process that merges two established technologies: plastic injection molding and powdered metallurgy. OptiMIM engineers can create geometrically complex, dense parts that cannot be produced using the conventional powder metal processes without secondary machining. With MIM, it’s possible to integrate and consolidate several components into a single molded piece, freeing designers from the traditional constraints associated with assembling several separately casted parts to achieve a net-shape component.</p><p>Our designers know that MIM is not 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 if MIM is the right process for you.</p><h2>What materials are used in MIM</h2><p>MIM materials have had their chemistries modified in order to withstand the complex metal injection molding process. There are a wide variety of materials available for MIM, but we specialize in stainless steel, copper, and low alloy steel materials. We can also process other specialty or custom materials tailored to your mechanical property specifications.  Ask an engineer about our custom feedstock capabilities!</p><h2>What size parts are most suitable for MIM?</h2><p>It's also crucial to consider the parting line and parting line witness. Every part has a parting line related to the molding process. However, it's important to be mindful of the application and understand how the parting line's location might affect the part's form, fit, or function. Ideally, the parting line should not be on a functional surface.</p><h2>What is the porosity of MIM components?</h2><p>Unlike other casting processes, MIM offers a very high density with 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><h2>What are the minimum and maximum wall thicknesses that MIM can achieve?</h2><p>Wall thickness is contingent upon the length of the wall, overall part size, and the part design. If the wall is localized, wall thickness as precise as 0.01” or less is possible. On the other end of the spectrum, wall thickness as large as 0.5” is possible. It is important to note as the wall thickness increases, so does the molding process cycle time, material consumption, and debinding and sintering cycles, which inherently increase total part cost.</p><h2>How do you accommodate for the shrinkage in the design of the mold?</h2><p>Over the years, we have studied each material that we use in the MIM process quite extensively. Each alloy and geometry shrinks differently. We developed and use predictive models and factor this into our tooling design.</p><p></p>

Learn about metal injection molding (MIM). This FAQ covers materials, part sizes, density, wall thickness, and shrinkage. 

Metal Injection Molding FAQ 

Metal injection molding (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 Molding FAQ

<h1>Designing for Metal Injection Molding</h1><p>Metal injection molding (MIM) is a technology that addresses many current manufacturing challenges. OptiMIM utilizes the injection molding process to produce net-shaped parts, ideal for high-performance applications demanding exceptional density, strength, and corrosion resistance. These parts consistently outperform industry standards in mechanical and physical properties. Designing for MIM requires careful consideration of several factors to ensure project success. Continue reading to explore the distinctive variables incorporated into our award-winning components.</p><h2>MIM Molding Variables</h2><p>Designing for metal injection molding requires careful consideration of various factors. The mold can be a two-plate or three-plate design. When designing the part, it's essential to determine the placement of details and features, such as gating and gate location. In some cases, a single gate or multiple gates may be necessary, depending on the part's geometry.</p><h3>Parting Lines</h3><p>It's also crucial to consider the parting line and parting line witness. Every part has a parting line related to the molding process. However, it's important to be mindful of the application and understand how the parting line's location might affect the part's form, fit, or function. Ideally, the parting line should not be on a functional surface.</p><h3>Ejector Marks</h3><p>Another important consideration is ejector marks. All parts must be ejected from the mold, so the ejector location must be carefully evaluated in relation to the part's function. In certain instances, sleeve ejection can be used to minimize or eliminate ejector marks.</p><h3>Wall Features &amp; Wall Thickness</h3><p>Additional factors to consider include thin wall features, especially those measuring 0.020 inches or less in thickness. When injecting thin features into a mold, there is a risk of breakage if the ejection process is not performed correctly. Our engineers carefully evaluate these factors and collaborate with clients prior to developing new programs.</p><p>For the full list of molding variables, download OptiMIM’s MIM Design webinar!</p><h2>MIM Design Considerations</h2><p>After we get past molding variables, we start looking at design considerations. And due to the complexity of the MIM process, there are quite a few design features that need to be addressed at each stage.</p><h3>Drag Effect</h3><p>g effect which is merely the fact that inherent to the MIM process, a part shrinks on the tiles when they’re placed into our sintering ovens. Keep in mind from the MIM 101 webinar, that on average, a MIM part will shrink about 20 percent. Specific shrink rates depend on the grade of the material and our engineering team designs the part with shrinking factored in.</p><h3>Sag Effect</h3><p>The second effect that occurs during the sintering process is the sag effect. During sintering, parts become relatively soft and because of gravity, cantilevered or unsupported features tend to want to run or sag. To design for the sag effect, we create a design that counters the effects of gravity. We can add special centers or ceramics that could be individual blocks, or custom machine ceramics to maintain those unsupported features.</p><p>Another option is working with you to modify your design to accommodate this goal without adding any additional costs. We look to add features like gussets on the part. Again, this would be ideal as long as it doesn’t affect your form, fit, or function of your application.</p><h3>Draft Angles</h3><p>The design characteristics for metal injection molding are very similar to plastic injection molding. However, the one main exception is the requirement of draft angles. In most cases for metal injection molding, we don’t require any draft angles at all. It’s a rare requirement.</p><p>The only time we might require a draft angle is if we have a high aspect ratio feature and we need to pull the mold, such as a thin wall section or a long core pin. We may introduce a half-a-degree draft just for additional relief, but for the most part, we don’t require a draft angle. The reason; we have a paraffin wax in the feedstock and that wax acts as a mold release agent so it allows us to have, for the most part, straight holes in the mold. There’s very little shrinkage that occurs at the molding stage. For that reason, it allows us to not require a draft angle.</p><h3>Wall Thickness</h3><p>Another thing about metal injection molding that’s very similar to that of plastic injection molding is uniform wall thickness. An ideal MIM part has similar wall thickness throughout so that we can control the shrinkage variability.</p><h3>Undercuts</h3><p>At OptiMIM, we design components with a collapsible core, a mold feature that enables us to incorporate undercuts directly into the molding process, thereby reducing the need for secondary operations and costs. Undercuts are often impractical or challenging with other manufacturing methods, but they are achievable with metal injection molding. Consulting with our engineering team prior to designing for undercuts is highly recommended.</p><p>To learn more about mold and design variables for the metal injection molding process, I invite you to download our free webinar. We’ll discuss the above topics in more detail and cover more on:</p><ul><li>Knurling</li><li>Custom feedstock</li><li>Gating</li><li>Secondary operations</li><li>Solving functional or assembly issues</li><li>And more! </li></ul><p>OptiMIM works with many of the world’s most demanding manufacturers—from medical and defense to automotive and consumer electronics. They know we deliver the quality and performance they need to create better products, more consistently, whatever the volume. From the initial design stage all the way through to full production, let our team of experienced engineers help you drive your business forward—contact us today!</p>

Learn about key considerations like mold design, parting lines, ejector marks, and wall thickness. 

Designing for Metal Injection Molding 

Metal injection molding (MIM) offers a unique solution for high-performance, high-density, and high-strength applications. 

Designing for Metal Injection Molding

<h1>Comparing Metal Injection Molding &amp; Powdered Metallurgy</h1><p>Manufacturers around the globe are always looking to create better-performing metal components. They want more design freedom without sacrificing cost. When traditional methods of casting no longer make the cut, manufacturers are turning to other molding processes to drive their products forward.</p><p>If you are familiar with powdered metallurgy (PM), you know the parts are formed from metal that is pressed together in a die and then sintered. Metal injection molding (MIM) is a complementary process that also uses metal particles—just much finer— to produce high-density components with three-dimensional design flexibility.</p><p>Learn more about the MIM manufacturing process here &gt;&gt;&gt;</p><h2>Where MIM Differs</h2><p><strong>Materials</strong></p><p><strong>PM and MIM utilize the same base powders and both processes allow for the use of custom alloys, however, the key difference in material is particle size. Coarser powders used in PM are widely known and the route to make them are inexpensive. MIM powders are much smaller so the process and energy to make them—in that size range—are more expensive to produce.</strong></p><p><strong>The cost of the powdered metal is a key driver when comparing MIM and PM materials. MIM powders are typically more expensive than PM powders since they are finer (-20 micron vs. +100 micron). However, because of the finer material, MIM produces significantly less porosity.</strong></p><p><em>Did you know?</em><strong> PM achieves all density in the compacting stage (85-92% density) while MIM density comes from sintering—a diffusion bond. (95%+ density)</strong></p><p><strong>Design Freedom</strong></p><p><strong>Engineers often confuse MIM and conventional PM given that the two start with powdered metal. PM relies on a high-pressure uniaxial compaction. PM is more suitable for simple shapes that are easily ejected from the die cavity. This is where MIM differs. With MIM, there are very few—if any—geometrical restrictions allowing for three-dimensional design freedom.</strong></p><p><strong> Other design improvements for MIM components include:</strong></p><ul><li><strong>Part consolidation</strong></li><li><strong>Uniform wall thickness</strong></li><li><strong>Coring and mass reduction</strong></li><li><strong>Holes and slots</strong></li><li><strong>Undercuts</strong></li><li><strong>Threads</strong></li><li><strong>Knurling, letter, and logos</strong></li></ul><table><tbody><tr><td><p><strong>Powdered Metallugry</strong></p></td><td>&nbsp;</td><td><p><strong>Metal Injection Molding</strong></p></td></tr><tr><td><p><strong>50-100pm</strong></p></td><td><p><strong>Powdered Particle Size</strong></p></td><td><p><strong>2-15pm</strong></p></td></tr><tr><td><p><strong>92% (Max)</strong></p></td><td><p><strong>Relative Density</strong></p></td><td><p><strong>&gt;95-99%</strong></p></td></tr><tr><td><p><strong>2-20mm</strong></p></td><td><p><strong>Wall Thickness</strong></p></td><td><p><strong>0.30 -10mm</strong></p></td></tr><tr><td><p><strong>Medium</strong></p></td><td><p><strong>Component Complexity</strong></p></td><td><p><strong>High</strong></p></td></tr><tr><td><p><strong>1-1,000g</strong></p></td><td><p><strong>Weight</strong></p></td><td><p><strong>0.01-200g</strong></p></td></tr><tr><td><p><strong>0.1-2.0%</strong></p></td><td><p><strong>Tolerance</strong></p></td><td><p><strong>0.3-0.5%</strong></p></td></tr></tbody></table><p><strong>Physical Properties</strong></p><p><strong>While the MIM and PM processes may seem similar, the major differences are found in the final properties of the finished component—mainly the final density. When you use the PM process, the friction between the powder and tooling make the final component non-uniform, while MIM parts are uniform in all directions.</strong></p><p><strong>Additionally, sintering for MIM takes place at much higher temperatures than PM (2350-2500F° vs. 1800-2000F°). The larger PM metal powders combined with lower sintering temperatures inherently cause the final PM component to have lower physical properties making MIM components about two times stronger, with significantly better toughness and fatigue strength. </strong></p><table><tbody><tr><td>&nbsp;</td><td><p><strong>MIM</strong></p></td><td><p><strong>PM</strong></p></td></tr><tr><td><p><strong>Elongation</strong></p></td><td><p><strong>High</strong></p></td><td><p><strong>Low</strong></p></td></tr><tr><td><p><strong>Hardness</strong></p></td><td><p><strong>High</strong></p></td><td><p><strong>Low</strong></p></td></tr><tr><td><p><strong>Surface Finish</strong></p></td><td><p><strong>High</strong></p></td><td><p><strong>Medium</strong></p></td></tr><tr><td><p><strong>Production Volumes</strong></p></td><td><p><strong>High</strong></p></td><td><p><strong>High</strong></p></td></tr><tr><td><p><strong>Range of Materials</strong></p></td><td><p><strong>High</strong></p></td><td><p><strong>High</strong></p></td></tr><tr><td><p><strong>Cost</strong></p></td><td><p><strong>Medium</strong></p></td><td><p><strong>Low</strong></p></td></tr></tbody></table><p><strong>Where Does MIM Fit?</strong></p><p><br />Where you add cost for more expensive feedstock and tooling, you realize the savings when it comes to high-density, high-complexity components that cannot be made by any other manufacturing process. PM may be a cost-effective alternative for simple parts but MIM can produce part geometries that eliminate secondary operations which can result in significant cost savings.</p><p>Many of our customers find substantial savings when they combine two or more subcomponents into one single MIM component. Additional savings are found when you consider materials, design, assembly and logistic benefits to the MIM process.</p><p>Illustrated in the graph below, there is a certain degree of complexity and volume that must be considered to make MIM the more economical manufacturing choice.</p><p>Leading Metal Injection Molding Manufacturer</p><p>On every project, we aim to deliver more consistent parts, more efficiently, at lower costs. Our goal is to do away with the expenses associated with secondary processes such as machining, achieving net-shape the first time.</p><p>So we build molds that are more efficient for high-volume production and put in as much complexity as needed up front to avoid costly machining and secondary operations.</p><p>Contact our team today to get the conversation started. <br /></p>

Learn how part size affects cost and efficiency in metal injection molding. 

Comparing Metal Injection Molding & Powdered Metallurgy 

Metal Injection Molding (MIM) and Powdered Metallurgy (PM) are both used to produce metal components, but they differ in particle size, density, design flexibility, and physical properties. 

Comparing Metal Injection Molding & Powdered Metallurgy

<h1>How Large Can You Create a MIM Component?</h1><p>When deciding if your part is a&nbsp;good fit for the metal injection molding process, part size is one of the first determining factors. We are frequently asked, “How large of a part can you create with MIM?” The quick answer is, in most cases under 160 grams. But it is important to understand how part size impacts the cost and efficiency of MIM.</p><h2>Mold Restrictions on Part Size</h2><p>The size of a part is not limited by the MIM process itself but more so from the size capacity of the mold. The mold does not change in size, so the larger the parts, the more “real estate” they take up in the mold. For example, if you think of the mold or tool as a sheet of paper, if you can fit only 2 cavities on the mold versus 6 or 8, especially as the part size increases, it will take far longer to create 100,000 parts which is not nearly as efficient as smaller MIM components.</p><h2>Part Complexity</h2><p>The complexity of a component helps to dictate which process should be utilized for mass production in order to be cost effective and efficient. So, while our sweet spot is less than or equal to 160 grams, if the part is larger and more complex <em>and</em> would typically require machining, MIM may offer economic savings. To truly utilize the MIM process, Design for Manufacturing (DFM) is one of the best practices our engineers follow to ensure your part does not require expensive secondary operations which can often represent as much as 80% of the component cost.</p><p><strong>Download the MIM Design guide for tips on designing for MIM.</strong></p><h2>Efficiency with MIM Materials</h2><p>MIM feedstock—which can be custom—is inherently more expensive than your average recycled aluminum, so it is not surprising that material cost does play a role in the MIM decision making process. At OptiMIM, we design our components to optimize the weight of the component and only use as little material as possible to create the component. With the MIM process, you can add complexity to the component without having to add material. While a larger part that is machined often results in a lot of scrap and waste.</p><p><strong>If a component is larger than 160 grams and complex in design, and if the economics are favorable, MIM may be a cost-effective alternative to other casting processes.</strong></p><p>MIM is capable of achieving intricate features such as dovetails, slots, undercuts, fins, internal and external threads, or complex curved surfaces—to name a few. MIM can also produce cylindrical parts of unique geometries with greater length to diameter ratios than most other casting technologies. To learn more about the capabilities of MIM, contact our engineering team to discuss your project needs in more detail.</p><h2>Part Size Related to Sintering and Debinding</h2><p>Second to molding, sintering and debinding furnaces have strict guidelines regarding mass loading for each batch size of components so that the binding material is removed at a proper—and precise—rate. The larger and thicker the parts, the fewer components you can put into the furnace at one time and the longer it takes to sinter and debind. Remembering that time is money, shorter cycle times are far more cost effective therefore less mass (part volume) usually equates to less process cost/time. Our team of engineers can help to modify your design to greatly increase production times. Thin walls and only using material where it is needed can optimize your part for the MIM process.</p><p>[Image: Components being put into sintering furnace]</p><p>MIM offers a lower cost solution to small complex components that would otherwise have to endure expensive secondary operations. While the process may seem niche, it is fully utilized by almost every industry including consumer electronics, medical, automotive, hardware, firearms, and telecommunications.</p><h2>Did You Know?</h2><p>Part designs can be limited when you’re constrained to traditional metalworking processes. However, with MIM design engineers have the freedom to create parts by placing material only where it is needed for function and strength. The end result is a complex shape that uses less material and does not have to be machined. <strong>To fully utilize the MIM process, connect with our engineering team to discuss your part design and gain insight on design for manufacturing and other design criteria, including:</strong></p><ul><li>Sintering supports</li><li>Draft –where and when</li><li>Corner breaks and fillets</li><li>Holes and slots</li><li>Undercuts –external and internal</li><li>Threads</li><li>Ribs and webs</li><li>Knurling, lettering and, logos</li><li>Gating- types and location</li><li>Sink and knit lines</li><li>Min and max wall thickness</li><li>Flash and witness lines</li><li>Interchangeable mold inserts</li></ul><h2>MIM Offers Design &amp; Cost Solutions</h2><p>The MIM process offers lower cost solutions for numerous applications compared to other metalworking processes. While part size doesn’t necessarily drive the MIM process it is definitely something to take into consideration. If you have a small, complex part that requires higher strength requirements and you want to produce large quantities, your project may very well benefit from the design freedom and cost solutions that MIM provides. If you are interested in learning more, we suggest you contact one of our design engineers who can walk you through the MIM process and its benefits more specifically to your project.</p>

How Large Can You Create a MIM Component? 

The size of a MIM component is generally limited to under 160 grams, but part complexity and design can influence this. Larger, more complex parts may still be suitable for MIM if they can be optimized for the process through design for manufacturing techniques. 

How Large Can You Create a MIM Component?

<h1>MIM Vs. Machining</h1><p><strong>MIM</strong>&nbsp;is a process that combines plastic injection molding and powdered metallurgy. It produces precise, complex metal parts, including stainless steel and other low alloy steels, often in large quantities. Machining, which removes unwanted material from a metal block, offers similar alloy options but may be less cost-effective for complex parts. Before MIM, machining was the primary option for non-castable parts.</p><h2>Differences Between MIM and Machining</h2><p>When it comes to similarities, MIM tends to correlate well with machined parts in regards to finished components. Typically, MIM components can be used in the same way as machined parts—aerospace, medical, firearms—and in some cases, MIM parts look very similar to machined parts. However, when it comes down to it, MIM offers many advantages for precision components that machining does not solve.</p><h3>Unique Geometry</h3><p>MIM offers unique geometry and complexity capabilities. Machining provides limited intricacy, flexibility, and design freedom and often times it is harder to machine complex components. As the components become more complex, MIM becomes more cost effective because the more complex your part, the more machine time it will take to create it.</p><h3>Strength &amp; Performance</h3><p>While both processes yield strong parts, MIM components do not endure machine induced stress or internal pressure which may result in deformation over time and potential part failure. MIM parts are molded using conventional molding machines and then are put into an oven where the wax is strategically melted from the component leaving a strong, solid component.</p><h3>Mold Investment</h3><p>When creating a MIM component, the complexity of the part is usually tied to the mold investment. Meaning that it is the mold or tool itself that is complex, so you have one upfront cost tied to the complexity of your component. With machining, if you add complexity you are adding extra cost and process time to the part price.</p><h3>Material Scrap</h3><p>Material scrap is not wasted with the MIM process. This is important because as a customer if you are sourcing a machined part, you are paying for that scrap. Through the MIM process, you do not have to spend dollars that could be used elsewhere.</p><h3>Capacity</h3><p>MIM is more scalable on ramp up capacity. Machining takes a fair amount of time to produce complex parts, so if you want to go to go from 10k parts a week to 20k you have to buy more CNC machines to get up to capacity. With MIM you do not have to do that.</p><h2>Other MIM Benefits</h2><p>When you utilize the MIM process, you also get:</p><ul><li>Repeatability</li><li>Improved cycle time</li><li>Part consolidation</li><li>Reduced need for secondary operations</li></ul><h2>Why Should You Choose MIM Over Machining?</h2><p>MIM becomes a more cost effective alternative for some applications compared to machining when you consider the volume and complexity of your project. MIM produces complex, net shape components that require no secondary machining requirements. When put to the right application, MIM can significantly decrease costs associated with secondary overhead all while increasing production rates.</p><p><strong>Our team of engineers offer design solutions for a variety of industries including consumer electronics, automotive, healthcare, and more. When our engineers are involved early in the project, they can help design a tool and part specifically for mass production. Contact our team today to get started on your next project.</strong></p>

Discover the key differences between MIM and machining. 

MIM Vs. Machining 

MIM is a more cost-effective alternative to machining for complex, high-volume parts, offering benefits like unique geometry, reduced material scrap, and improved cycle time. 

MIM Vs. Machining

<h1>Food Grade Stainless Steel</h1><p><strong>Food-grade stainless steel is a safe metal for food preparation and water storage.</strong>&nbsp;Due to its inability to be die cast, many companies opt for investment casting or machining, overlooking the advantages of&nbsp;metal injection molding&nbsp;(MIM) for high-volume, complex stainless steel molds.</p><h2>Metal Injection Molding for Food Grade Metals</h2><p>When seeking a food-safe metal, customers often prioritize strength and corrosion resistance. Although&nbsp;aluminum, zinc,&nbsp;and&nbsp;copper&nbsp;can be used for food-safe components, they require post-casting coating to prevent leaching into food. Stainless steel, on the other hand, eliminates the need for coating or plating, reducing secondary operations and costs.</p><p>To ensure the safety of food and water, it is crucial to minimize residual metal and flash. MIM tools are designed with less flashing due to the use of stronger metals compared to&nbsp;die casting alloys, making post-production corrections more difficult.</p><h2>Popular Food Safe Stainless Steel</h2><p>One of the most important aspects of food grade stainless steel is the sanitary finish. It needs to be easily and reliably cleaned and sanitized. If not, the surface may be susceptible to harmful bacteria growth—which is not compatible with FDA regulations.</p><p>Most food processing equipment is made from 304 or 316 austenitic stainless steels. While OptiMIM offers a variety of stainless steels for metal injection molding, MIM-316L is most widely used when it comes to components that are safe for food and clean water. Not only does MIM-316L have high strength properties, but it is also very corrosion resistant—which is important for metals that come in contact with acids that break down and change the alloy composition over time. The high alloy and low carbon content of MIM-316L make it a great fit for food grade applications.</p><p><strong>Use our metal selector tool to compare mechanical and physical properties of other MIM alloys.</strong></p><h2>Designing For MIM</h2><p>Metal injection molding offers design freedom from the traditional constraints of shaping stainless steel. Not only can you create complex stainless steel parts at high volumes, but MIM makes it possible for designers to mold parts with:</p><ul><li>Holes and slots</li><li>Undercuts, both internal and external</li><li>Threads</li><li>Ribs and webs</li><li>Knurling, lettering and logos</li></ul><p>With metal injection molding you can achieve tighter tolerances by only having to place material where it is needed for function and strength.  </p><p><strong>Download our free MIM Design Guide to learn more about the advantages of MIM</strong></p><p>For small, complex parts demanding high strength, corrosion resistance, and food safety, consider consulting with an&nbsp;OptiMIM design engineer&nbsp;to explore the&nbsp;MIM process&nbsp;and its advantages for food-grade applications.</p>

Discover the advantages of metal injection molding (MIM) for producing high-quality, food-safe stainless steel parts. 

Food Grade Stainless Steel 

Food-grade stainless steel is a popular choice for food processing equipment due to its strength, corrosion resistance, and easy sanitation. Metal injection molding (MIM) offers a cost-effective and efficient way to produce complex stainless steel parts for this industry. 

Food Grade Stainless Steel

<h1>Material Spotlight: Kovar</h1><p>One of the benefits of MIM is the amount of alloys that are available. MIM alloys can be blended to meet all of a customer’s specifications and needs. Kovar, commonly referred to as MIM-F15, is one of the many MIM materials that</p><p><strong>OptiMIM</strong>&nbsp;offers.</p><h3>Low Coefficient of Thermal Expansion</h3><p>Kovar, or F-15, is a low expansion iron MIM alloy that is most commonly used in electronics applications. Kovar has a high nickel and cobalt content and is traditionally an alloy that was used for metal-to-glass sealing because of its low coefficient of thermal expansion. It also provides a hermetic seal that is used to protect devices in many different industries.</p><h3>Aerospace Alloy of Choice</h3><p>Recently, Kovar has been selected as the alloy of choice for aerospace industry applications because of its properties. Kovar can withstand rapid temperatures – from absolute zero to extremely high heat – without changing or weakening in structure. As an example, Kovar is used in the aerospace industry in the small components on radar systems and satellites so that the change in temperature does not warp the metal or make the radar work improperly.</p>

Learn how metal injection molding (MIM) transforms feedstock into a "green part" using high pressure injection and specialized tooling. 

Material Spotlight: Kovar 

Kovar, a low expansion iron alloy used in electronics and aerospace, is a metal injection molding (MIM) material that withstands extreme temperatures without structural change, making it ideal for applications like radar systems and satellites. 

Material Spotlight: Kovar

<h1>MIM Process Series Part 6: Sintering</h1><p>Sintering is the crucial final step in the Metal Injection Molding (MIM) process, where "brown parts," which have already undergone debinding, are transformed into solid, finished components. These parts are carefully placed on specialized ceramic trays designed to minimize shifting during the intense heat of the sintering process. The trays are then loaded into a high-temperature furnace where the parts are gradually heated. This controlled heating allows any remaining binder material to evaporate, ensuring a pure and dense final product.</p><p>As the temperature climbs higher within the furnace, it reaches a point where the individual metal particles within the part begin to fuse together. This fusion process, driven by atomic diffusion, solidifies the component and gives it its final strength and form. During sintering, the part typically shrinks by about 20%, a critical factor that engineers must consider during the initial design phase. Once the sintering process is complete, the furnace cools, and the parts are carefully removed. At this stage, they are considered finished, although some parts may undergo additional processing like machining or surface coating to meet specific application requirements.</p><h2>Types of Furnaces</h2><p>There are two kinds of furnaces that are available for MIM production: continuous furnaces and batch furnaces. Continuous furnaces can debind and sinter in the same step. The temperatures reach near melting temperature of the base metal, and these furnaces are only ideal for high volume manufacturing. The batch furnaces also reach temperatures near the melting temperature of the base metal but have a much shorter process time then continuous furnaces. These furnaces run under vacuum and during the process a flow gas is pumped through the furnace – these gases can be nitrogen, argon or hydrogen. There is also supporting equipment for this furnace, including a hydrogen generator, a nitrogen generator, and a back up emergency power generator for cooling the vessel in times of a power failure.</p><h2>Issues During Sintering</h2><p>There are issues that can occur during sintering, which is why the design step of our business is problems with the final part. These problems include not taking into consideration gravity or friction. The resulting part can be warped. There are options that our engineers use to minimize this. Some of these options include spacers, adding a support rib to the part, and coining. There can also be sag issues with a part. Using special setters that support the pieces most likely to sag upright can solve this issue. Parts can also be set in a special ceramic tray, or they can include a runner.</p><p><strong>After exploring the MIM process through this blog series, are there any remaining questions? Perhaps there's an aspect that wasn't fully covered or a specific topic of interest. If so,</strong></p><p><strong>contact the OptiMIM engineering team.</strong></p><p><strong>You may also be interested in:</strong></p><p><strong>MIM Series Part 1</strong></p><p><strong>MIM Series Part 2 – Feedstock</strong></p><p><strong>MIM Series Part 3 – Compounding</strong></p><p><strong>MIM Series Part 4 – Molding</strong></p><p><strong>MIM Series Part 5 - Debinding</strong></p>

Learn how metal injection molding (MIM) transforms feedstock into a "green part" using high pressure injection and specialized tooling. 


MIM Process Series Part 6: Sintering 

Sintering, the final step in the MIM process, involves heating "brown parts" in a furnace to remove remaining binder and fuse metal particles, resulting in a dense, solid part with approximately 20% shrinkage. 

MIM Process Series Part 6: Sintering

<h1>MIM Series Part 5: Debinding</h1><p>Debinding is the fifth part of the MIM101 blog series. This post explains why debinding is a critical step in the MIM process. As explained in the previous post about molding, after the part comes out of the machine it is considered “green” and is about 20% larger than the final part. To go into the sintering phase without defects, the part needs to be debinded. After the debinding process is complete, the part is considered “brown”.</p><p>For more information about the&nbsp;MIM process,&nbsp;contact OptiMIM’s team today!</p><p>The debinding process removes the primary binding material from the molded component. Typically, there are steps to the debinding process, and the part goes through more than one cycle to ensure as much of the binding material is removed as possible before sintering. After the debinding step the part is semi-pourous, which allows the secondary binder to easily escape during sintering cycle. Many question why debinding is needed, but without this critical step the part would not be as sturdy. Debinding also prevents furnaces from clogging which can lead to added expenses on the manufacturing side. It also is a faster process to debind and then sinter, versus just sintering alone. Debinding can be done using multiple methods. The three most common methods are explained in detail below.</p><h3>Debinding Methods</h3><p>There are three types of debinding methods that are typically used – thermal, supercritical fluids (SFC), and solvent. Thermal debinding is a method within a temperature-controlled environment. It has inexpensive equipment but has a long processing cycle and results in poor “brown” strength. Supercritical fluids debinding is a method that occurs in a gaseous acid environment. This method has good “brown part” strength and is environmentally friendly, but has a patented process with few suppliers and limited materials. The last method is the one most commonly used throughout MIM manufacturers – solvent debinding. Solvent debinding is a process where acetone, heptane, trichloroethylene, and water are used. It results in good “brown part” strength and is a consistent process that utilizes a closed loop system. Solvent debinding is not as environmentally friendly as the other methods, which is one of the only downsides in using this type of debinding.</p><p>In the final part of this series, you’ll learn about the sintering phase. This phase is the final one in the MIM process, and creates the finished part.</p><p><strong>To address any further inquiries about the debinding process, OptiMIM's engineering team is available to provide assistance and resources.&nbsp;Contact them today for support.</strong></p>

MIM Series Part 5: Debinding 

Debinding is a crucial step in the Metal Injection Molding (MIM) process where the primary binding material is removed from a molded component to ensure a sturdy final product and prevent sintering defects. 

MIM Series Part 5: Debinding

<h1>MIM Series Part 4: Molding</h1><p>Molding, the fourth part of this blog series on MIM, focuses on loading compounding pellets into a MIM machine to produce a “green part”. This part is about 20% larger than the final part, but has the same geometry.  The percentage is based on the type of metal used, which is known before mold completion. This allows for the tool to be created correctly, so the final part meets exact specifications.</p><p>For more information about the MIM process,&nbsp;contact OptiMIM engineers today!</p><p>When pelletized feedstock is fed into either standard or multi-slide MIM machines, it is heated and injected into a mold cavity. This high-pressure injection creates the “green” part. The part cools quickly and is ejected from the mold. Only the binders melt in the molding phase, and tooling can have multiple cavities for higher production rates. 70% of MIM defects result from tooling and another 15% from molding, making these steps critical to a correct, defect-free final part.</p><h3>Molding Machines (H3)</h3><p>The metal powder is mixed with plastic and paraffin binders at a ratio of approximately 40% binder and 60% metal. This percentage can vary based on the powder size and desired tool shrinkage. MIM parts can shrink from their original molded condition (known as the green state) to a finished sintering condition by 16-21%. This ratio is known as powder loading. There are two common methods for mixing MIM materials: using a planetary mixer or a tubular mixer. These mixers blend the material, which can be done at room temperature or heated. When heated, the material is mixed to a temperature that causes the binders to melt. Mixing continues until the metal powder is uniformly coated with the binders. The mass is then cooled and pelletized. Both mixing processes are batch processes, ensuring the metal powder is uniformly coated with the binders. The resulting pelletized mix, known as feedstock, is then ready for the molding machine.</p><p>The planetary mixer uses a batch process and is slower. It produces inconsistent blends and introduces more variables than other available mixers. The tubular mixer, which is also a batch process, is the preferred method used by OptiMIM. It offers faster throughput and creates consistent blends with fewer variables.</p><h3>Compounding</h3><p>OptiMIM utilizes conventional MIM machines that have a typical cycle time of about two shots per minute. It is ideal for larger parts and for parts that have multi-cavities and are also high-volume production. Conventional MIM machines require complex tooling, long runner systems, and long material residence time in the machine and mold. Some of the tools for conventional MIM machines could have shorter lives depending on the complexity of the part.</p><p>In part five of this series, you’ll learn how the part goes from “green” to “brown”. The next blog will focus on the debinding portion of the MIM process. </p>

MIM Series Part 4: Molding 

The fourth part of the MIM series focuses on the molding process, where metal powder and binder are injected into a mold to create a "green part" that is slightly larger than the final product. 

MIM Series Part 4: Molding

<h1>MIM Series Part 3: Compounding</h1><p>The&nbsp;previous blog post&nbsp;focused on the feedstock required to perform metal injection molding (MIM). This post will discuss the first step of the MIM process – compounding. In short, compounding is the process of taking the metal powder, plastic and paraffin binders and mixing these ingredients in a mixer. 1 This blended mix is then processed through a twin screw extruder. The paraffin binder is known as the primary binder and the plastics are the secondary binder. The mixer, as 1 alluded to in the feedstock post, blends these ingredients so the material has a uniformed density throughout the batch which is the first key step in process control.</p><p>To learn more about the MIM process, keep reading or&nbsp;contact our team of engineers.</p><h2>MIM Feedstock</h2><p>The metal powder is mixed with plastic and paraffin binders at a ratio of approximately 40% binder and 60% metal. This percentage can vary based on the powder size and desired tool shrinkage. MIM parts can shrink from their original molded condition (known as the green state) to a finished sintering condition by 16-21%. This ratio is known as powder loading. There are two common methods for mixing MIM materials: using a planetary mixer or a tubular mixer. These mixers blend the material, which can be done at room temperature or heated. When heated, the material is mixed to a temperature that causes the binders to melt. Mixing continues until the metal powder is uniformly coated with the binders. The mass is then cooled and pelletized. Both mixing processes are batch processes, ensuring the metal powder is uniformly coated with the binders. The resulting pelletized mix, known as feedstock, is then ready for the molding machine.</p><p>The planetary mixer uses a batch process and is slower. It produces inconsistent blends and introduces more variables than other available mixers. The tubular mixer, which is also a batch process, is the preferred method used by OptiMIM. It offers faster throughput and creates consistent blends with fewer variables.</p><h3>Compounding</h3><p>Compounding is handled in-house at OptiMIM. This approach offers several advantages. Custom blends can be created for customers with specific requirements or who need a particular metal for their part. Costs are also lower, as the materials needed are kept in-house, eliminating the need for a third party to mix metals and compound the material. Additionally, it is possible to match the shrinkage of different materials as well as existing tooling, resulting in a better and more consistent part for the customer.</p><p>Part Three of this series will focus on the molding aspect of the MIM process. For more information or inquiries about compounding,&nbsp;contact the team&nbsp;or sign up for updates.</p>

Learn about compounding, the crucial first step in the metal injection molding (MIM) process. 


MIM Series Part 3: Compounding 

Compounding is the first step in the metal injection molding (MIM) process, where metal powder is mixed with binders and then processed to create a feedstock for molding. 

MIM Series Part 3: Compounding

<h1>MIM Series Part 2: Feedstock</h1><p>A previous blog post –&nbsp;MIM 101&nbsp;– provided a high-level overview of the MIM process. As promised, this post in the series focuses on feedstock. The MIM process involves four steps: compounding, molding, debinding, and sintering. Feedstock, the end result of compounding, is essential to the entire MIM process. Selecting the right powder mixture ensures the best possible part is manufactured.</p><p>To learn more about the MIM process, keep reading or&nbsp;contact our team of engineers.</p><h2>What Is Feedstock?</h2><p>Metal Injection Molding utilizes a blend of metal powders combined with a plastic and wax binder. This mixture, known as feedstock, forms the foundation of the final part. OptiMIM takes pride in mixing its own feedstock, allowing for a diverse selection of metals for customer use.</p><p>Customers can choose from a variety of metal mixtures. Some common feedstocks include NiFe, 316SS, 420SS, 17-4SS, 4140, titanium, and copper. OptiMIM also offers custom powder blends to achieve specific mechanical properties, high-temperature resistance, and weight requirements.</p><h3>Manufacturing the MIM powder</h3><p>Metal powder is typically manufactured in two ways: water atomization and gas atomization. Water atomization involves pouring molten metal through a nozzle and spraying it with water jets to create metal droplets. These droplets are then quenched with water and collected at the bottom of a tank. The rapid cooling results in rough and irregularly shaped particles with better "brown part" strength and consistency during sintering, but also leads to higher oxidization and oxygen levels.</p><p>Gas atomization is similar, but uses an inert gas instead of water to atomize the molten metal into fine droplets. These droplets cool as they fall in an atomizing tower, resulting in spherical particles with a high level of cleanliness, better powder distribution, and superior oxygen and carbon control. However, this process can lead to poor "brown part" strength and sintering issues like sag and drag.</p><p>After atomization, the particles are separated and classified by size, typically ranging from 4 to 25 microns for MIM applications. Screening and air classification are two common methods. Screening utilizes various sized screens to separate particles, while air separators use a rising column of air to sort heavier, denser particles from finer ones. Smaller particles generally cost more, though some manufacturers have refined their processes to produce them at higher yields.  To ensure accurate particle size distribution, a particle size analyzer is used for quality checks.</p><p>Mix sheets guide the combination of metal powders, wax, and plastic binders in specific ratios to achieve proper shrinkage. These ingredients are mixed, blended, and processed through a twin-screw extruder to create feedstock pellets.</p><p>Part Three of this series will focus on&nbsp;compounding.&nbsp;Any questions regarding feedstock? Anything that needs further explanation?&nbsp;Contact a team of engineers for more information.</p>

Discover the different types of feedstock and how they impact your final product. 


MIM Series Part 2: Feedstock  

Metal injection molding (MIM) uses a feedstock of metal powder mixed with a binder, which is crucial for producing quality parts and can be created through water or gas atomization. 

MIM Series Part 2: Feedstock

<h1>MIM Series Part 1</h1><p>Let's explore MIM. MIM offers a unique combination of metal strength and durability with the design flexibility of injection molding. At OptiMIM, two different types of MIM are available – standard and multi-slide. Both offer similar advantages, such as creating complex geometries, combining multiple parts, enhancing features, dramatically reducing cycle times, and obtaining greater precision and consistency. More details about each type will be shared in a future blog post. For now, let’s discuss the steps in the MIM process.</p><p><strong>For more information on the  MIM process, contact our engineering team  today!</strong><br /></p><h2>MIM Process</h2><p>The MIM process involves four steps: compounding, molding, debinding, and sintering. These four steps, along with feedstock, will be the focus of the next five parts of this blog series. Here is a brief overview of each process.</p><h3>Feedstock/Compounding</h3><p>MIM utilizes metal powders combined with a plastic and wax binder, known as feedstock, as the foundation for creating parts. By mixing feedstock in-house, a wide range of metals can be offered, including NiFe, 316SS, 420SS, 17-4SS, titanium, and copper. Pre-alloyed metal powders are also available. Once mixed, the feedstock is processed through a twin-screw extruder and pelletized.</p><h3>Molding</h3><p>The pellets are loaded into either a standard MIM machine or a proprietary multi-slide MIM machine. At this point, the component is called a “green part”. The final part will have the same geometry as the green part but will be about 20% smaller. </p><h3>Debinding</h3><p>In this step, some of the binder from the feedstock is removed. Heat, chemicals, or a combination of both are used to remove the binders and prepare the part for sintering. Once the binder is removed, the part is referred to as a “brown part”.</p><h3>Sintering</h3><p>The brown part is placed into a continuous or batch vacuum furnace and subjected to temperatures near the material’s melting point. This removes the remaining binder and densifies the part, resulting in the 20% shrinkage mentioned earlier. Sintering takes approximately 15-20 hours.</p><p>Part Two of this series will focus exclusively on the feedstock aspect of the&nbsp;MIM process. To answer any questions or for further discussion,&nbsp;contact our engineering team today!</p>

Learn the basics of metal injection molding (MIM) and discover how this manufacturing process can create complex parts with strength and precision. 

MIM Series Part 1 

Metal injection molding (MIM) combines the strength of metal with the flexibility of injection molding to create complex parts through a four-step process: compounding, molding, debinding, and sintering. 

MIM Series Part 1

<h1>What Makes a Good Fit For MIM</h1><p>(What Makes a Good Fit For MIM (alt. description))</p><p>With the abundance of metalworking solutions available, engineers frequently inquire about MIM (Metal Injection Molding) and its ideal applications. MIM merges thermoplastic injection molding and powder metallurgy to create intricate, dense, and high-performing metal components. However, the key question lies in identifying when MIM yields the highest ROI compared to other processes for a specific project.</p><p>The suitability of a part for MIM is primarily determined by factors such as size, weight, and volume. Overly large parts consume excessive space on MIM molds, impacting cost-effectiveness. Nonetheless, the complexity of the part often dictates the potential ROI manufacturers can achieve with MIM.</p><h2>Part sizes for MIM<br /></h2><p>The limiting factors for the MIM process are determined by the size capacity of the mold and how much raw material is required per component. For these reasons, MIM components aretypically smaller than the average palm and weigh under 60 grams.</p><h3>MIM feedstock cost</h3><p>MIM feedstock is a combination of very fine, customizable metal powders and polymers, which tends to be more expensive than your typical molten casting alloys. Because of this, material cost is one of the biggest limiting factors in the MIM decision making process. At OptiMIM, our engineering team can help to optimize your component’s features to minimize wall thickness for the most ergonomic design.</p><p>Mold space and materials limit most MIM components to less than 3 inches in length, but what the MIM process lacks in size capacity, <strong>it more than makes up for in part complexity, repeatability, and scalability.</strong></p><h2>Take advantage of increased complexity for maximum ROI</h2><p>While MIM tooling has a higher initial ticket price than our competitors who machine wrought stock, machine investment casting, and machine conventional permanent molding, MIM part cost remains constant with additional complexity and molded features.</p><p>MIM is capable of achieving 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 of unique geometries with greater length to diameter ratios than most other casting technologies, as well as consolidate several components into one for better functionality.</p><p><strong>If you’re looking to learn more about what the characteristics that make a component a good candidate for the MIM process, you can download our FREE on-demand webinar on What’s A Good Fit for MIM?</strong></p>

Learn how Metal Injection Molding (MIM) is ideal for producing small, intricate parts with high precision and cost-effectiveness. 

What Makes a Good Fit For MIM 

Metal injection molding (MIM) is ideal for large batches of small, complex parts, while investment casting (IC) is better suited for smaller lot sizes of larger parts. 

What Makes a Good Fit For MIM

<h1>Utilizing MIM to Manufacture at Scale</h1><p>Producing a high-quality part with a short production time and lowest total cost is crucial for the overall success of a company and their final part. <strong>And for manufacturing small, complex components at scale, metal injection modeling (MIM) is the most efficient process to get the job done.</strong></p><p>At OptiMIM, we’re experts in taking your project all the way from the drawing board into mass production. Not only does our metal injection molding process lend itself to scalability with automation, large batch capacity, and relatively low up-front investment, but our engineers are experts in streamlining your supply chain and validation processes.  </p><p>To answer all of your questions about why it is easiest to manufacture at scale with metal injection molding, we asked OptiMIM Business Development Manager,  John O’Donnell, a Mechanical Engineer with over 27 years of industry experience, specializing in product design and development. John spent the last 14 years with OptiMIM working in engineering and technical sales.</p><h2>Why is it important to manufacture for scale?</h2><p>We often times talk about the importance of designing for manufacturability (DFM), but similarly, scalability must also be at the forefront of product design. After considering early supplier involvement and transparency, adding scalability to the process enables us to build tooling that supports a sudden surge in production demand, or even modifications to design features. By consulting design engineers at an early stage of the part development operation, we can better understand the variables and develop a roadmap that works for the customer and produces a successful go-to-market part.</p><h2>How do I scale production with control?</h2><p>There are quite a few areas where suppliers can fall short on delivering a quality part—like failing to plan for possible manufacturing disruptions or volume changes. It is important to look at the life of the project in its entirety and create a roadmap. During the development of the roadmap, documentation of process variables becomes the key to success. The process should be less about getting parts to a customer as quickly as possible, and more about centering the whole process and decreasing lead times over time. An emphasis on the documentation of procedures and trainings eliminates the loss of knowledge of key steps and controls when production increases. Manufacturers have to be able to pivot and adapt with the unexpected, and with the right processes in place, success is inevitable.</p><h2>How can I increase production volume?</h2><p>Using scaling techniques, like Predictive CPK Modeling, can make sure volume increases are done effectively and efficiently. Tolerances and dimensions are analyzed to produce the degree of CPK, or sustained process capability, we can hold during production. All variables within the production process are identified, including everything from feedstock consistency to molding variations. With modeling, we are able to streamline the supply chain and scale faster. And for most of you time-to-market is what matters most.</p><h2>Eliminate scalability setbacks with OptiMIM</h2><p>We’ve seen several medical manufacturers stumbling into the trap of using a “shortcut” manufacturing process like machining from bar stock to validate their prototype and get to market as fast as possible. While these processes may create a functional prototype, they are not scalable over the life of the program. So when these medical manufacturers move to a new process to scale for mass production, they must start the process validation over again from scratch, setting them back several months. On top of that, different processes for prototype and final component might mean different design considerations, depending on the capabilities of each process.</p><p>With OptiMIM, we can produce fully functional prototypes to validate your design in a way that is scalable throughout the life of the product. Rather than having to pivot from another process and suffer the re-validation and potential re-designs, OptiMIM engineers can help guide your program all the way from conception to mass production so that you can take advantage of the full suite of benefits of the MIM process. The earlier we’re involved, the more value we can engineer into your component.</p><h2>What benefits does automation add to the project?</h2><p>Other manufacturing techniques, such as machining, are able to produce intricate geometries, but when it comes to scaling, metal injection modeling comes out on top. With a fully automated process, you are able to scale from low volume to high volume very quickly and without a lot of overhead. By implementing automation in your production process, you increase production times, lower material scrap, and achieve better product quality and repeatability with shorter lead times so that you'll have your orders in-hand, faster.</p><h2>Can you give an example of automated process controls?</h2><p>For example, one of our automated processes, Pressure Sensor Cavity Monitoring (PSCM), allows for increased part complexity, stabilized process controls, and increased mold cavitation. We are then able to increase the 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 molding 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 stable and for a longer period of time.</p><h2>How do I lower the cost to scale with MIM?</h2><p>When deciding if MIM is the right process for a project, it is important to measure scalability relative to other technologies. It is also important to consider part complexity and the time over which the product will need to be produced to determine the most cost-effective method.</p><p>For example, choosing machining for a component that includes multiple setups, and will need to be produced over a three to five-year period, could be costly due to the machine time needed to complete the order. A machining center also has limited capacity, possibly leading to added cost down the line for additional machines or multiple suppliers—adding unnecessary risk to the supply chain.</p><p>One of the distinct benefits to MIM is scaling with the same footprint that you prototype with, in turn adding ROI over the life of the project. With MIM, cavitation can be added to existing molding machines, rather than adding more molding machines to the process—this means a lower cost investment for moderate to high volume.</p><h2>Final scalability thoughts</h2><p>Scaling does not mean that you have to produce millions of pieces a year. Scaling just means having a strong control of the process moving towards full scale production. The key is to maintain product and process controls without capability degradation. If you think that your part could benefit from the MIM process, contact one of our design engineers who can walk you through the benefits in relation to your project.</p><p> To learn more about how to manufacture at scale, download our free webinar Securing Scalability: Utilizing MIM to Manufacture at Scale. We’ll discuss the above topics in more detail and cover more on:</p><ul><li>       Streamlining regulatory validations, like FDA approval</li><li>       Manufacturing with MIM at a lower total cost to scale</li><li>       Shortening your supply chain with automation and part consolidation</li><li>       MIM case studies</li></ul><p></p>

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Whitepaper

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Case Study

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