Metal Injection Molding Process
MIM combines plastic injection molding and powdered metallurgy to efficiently manufacture precise, complex parts in large quantities, often consolidating multiple components into a single part.
- Precise and complex parts
- High-density parts
- Greater design freedom
- Customization
- Consistency over large production runs
- Part consolidation
- Reduced assemblies
- Material versatility
- Enhanced mechanical properties
- Faster cycle times
- Tighter tolerances
- Decreased defects
- Cost-Efficiency
- Parts less than 100 grams
- Tonnage range: 40T to 110T
- Maximum section thickness generally less than 0.25 inches
- Tolerances +/-0.3% with precision down to +/-0.001 inches
- Annual volumes typically 10,000+ parts per project
- Feedstock produced in-house
- Low Alloy Steels
- Stainless Steels
- Special & Custom Materials
What Is Metal Injection Molding?
Metal injection molding (MIM) combines the precision of plastic injection molding with the strength of powdered metallurgy to efficiently produce complex metal parts in high volumes. This process allows for the creation of intricate designs, often consolidating multiple components into a single part.
Feedstock
Very fine metal powders are mixed with thermoplastic and wax binders to create a homogeneous, pelletized material that can be injection molded like plastic. This method achieves 95-100% of theoretical density, allowing for ultra-high density and close tolerances in high-production runs, unlike standard powder metallurgy.
Molding
The feedstock is heated and injected into a mold cavity under high pressure, enabling the production of highly complex shapes with shorter cycle times. The resulting component, known as a “green” part, mirrors the final design but is approximately 20% larger to account for shrinkage during the subsequent sintering phase.
Debinding
The debinding process involves a controlled method to remove most of the binders from the “green” part, preparing it for sintering. After debinding, the component is known as a “brown” part, ready for the final step in its production.
Sintering
During the sintering process, the fragile “brown” part, held together by a small amount of binder, is subjected to temperatures near the melting point of the material. This step eliminates the remaining binder and finalizes the part’s geometry and strength, resulting in a fully dense and robust component.
BEYOND THE BASICS
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