Why Choose Metal Injection Molding (MIM) for Complex Parts?

Introduction

If you want to know how tiny parts are made, read on. Metal Injection Molding (MIM) is the answer. In this blog, you will know how it works. You’ll see why MIM is great for small and tricky shapes. Now let’s explore how it assists in making parts fast!

What is Metal Injection Molding (MIM)?

Metal Injection Molding (MIM) makes tiny metal parts using heat and molds. Feedstock is a mix of metal powder and binder. You heat it to 200°C. You inject this into molds. It is cooled and a green part is formed. Debinding takes away the binder, and in this way, the piece is ready for sintering.

The part shrinks by 20% during sintering, fusing the metal particles together. This provides the part strength. The final component can be as small as 0.03 grams. MIM may be the product you use for tiny gears or parts for cars and aeroplanes.

Metal Injection Molding (MIM) vs Traditional Manufacturing Techniques!

·        Die Casting Vs. MIM

Die casting and Metal Injection Molding (MIM) make parts in different ways. Die casting uses melted metals, heating them over 660°C. MIM works with metal powders at lower, 300°C heat. You can make complex shapes like gears with MIM, but die casting leaves a rough finish.

Metal Injection Molding (MIM) is better for small parts, while die casting is for bigger ones. Die casting is good for high volumes, but MIM gives more precision. Choose MIM if you need fine, detailed parts.

·        CNC Machining Vs. MIM

CNC machining and Metal Injection Molding (MIM) create parts with different methods. CNC machining cuts solid blocks with tools, giving tolerances of ±0.005 mm. MIM molds powders into complex shapes like connectors. CNC works for single pieces, but MIM saves costs in mass production.

Also, MIM is mostly automated, unlike CNC, which needs more manual work. Metal Injection Molding (MIM) is faster for producing many parts with fine details. Use CNC if you want custom pieces; MIM fits for large quantities.

·        Low-Cost Tooling

Metal Injection Molding (MIM) can save you money on tooling. MIM tools cost between $10,000 and $50,000. Die casting molds can cost over $100,000. This makes MIM a better option for making smaller, detailed parts like phone parts or medical tools.

Also, MIM tools last longer, so you won’t need to replace them as often. Over time, using Metal Injection Molding (MIM) can save money, especially in large production runs. You can make detailed, complex parts with lower upfront costs.

·        Near-Net-Shape Production

Metal Injection Molding (MIM) helps you get parts close to their final shape. With tolerances of ±0.3%, MIM makes complex shapes like gears or medical implants. These parts don’t need much extra work, saving you time. MIM can make tiny parts weighing 0.1 grams, so there’s less waste.

Near-net-shape production also reduces extra work like polishing. Choose Metal Injection Molding (MIM) for creating precise parts with little waste. This saves material and time, making it a great option for high precision.

·        Minimal post-processing

Metal Injection Molding (MIM) reduces post-processing work. You don’t need much finishing because the parts come out smooth. MIM parts, like small auto components, have smooth surfaces right from the mold, as smooth as 1-2 micrometers. Traditional methods, like CNC, often need extra polishing.

MIM saves you time and effort by skipping these steps. When you need fast production with minimal finishing, choose Metal Injection Molding (MIM) for clean, precise parts right out of the mold.

Materials Used in Metal Injection Molding (MIM)!

·        Stainless Steel

You can use stainless steel for making strong, small parts. It has iron, chromium (at least 10.5%), and nickel. Stainless steel types like 316L and 17-4 PH are very tough.

Its density is 7.8 g/cm³, which helps create complex shapes. This metal resists rust and works well in medical tools and aerospace. You’ll get strong, long-lasting parts from it. Stainless steel is perfect when you need something that won’t wear out easily.

·        Tool Steels

Tool steels are very hard and last a long time. They have lots of carbon and chromium, which makes them strong. In Metal Injection Molding (MIM), tool steels like A2 and D2 are used for cutting tools.

They can become as hard as 60 HRC. With a density of 7.85 g/cm³, these steels can handle high heat. You can use tool steels in making molds or dies for shaping things. Their strength makes them a top choice for tough jobs.

·        Titanium Alloys

Titanium alloys are very light but very strong. One type, Ti-6Al-4V, contains 6% aluminum and 4% vanadium. It’s perfect for making things like medical implants and airplane parts.

Its density is 4.5 g/cm³, so it’s much lighter than other metals. Titanium alloys resist rust and stay strong even after a long time. When you need lightweight parts that last, this metal is a great option. You’ll find it in places where strength is really important.

·        Tungsten Alloys

Tungsten alloys are very heavy and strong. They have up to 97% tungsten mixed with nickel and iron. With a density of 19 g/cm³, tungsten alloys can block radiation and heat very well.

Their melting point is 3,422°C, so they work in very hot places. You can find tungsten alloys in medical tools or parts for planes. They hold up under a lot of pressure and heat, making them a smart choice for tough jobs.

·        Nickel-Based Superalloys

Nickel-based superalloys are great for high-heat jobs. Alloys like Inconel 718, which has 50-55% nickel, can handle heat up to 700°C. These metals have a density of 8.19 g/cm³ and resist both rust and heat.

They’re used in things like jet engines and turbines. These alloys stay strong, even in tough conditions. When you need something that won’t break or melt, nickel-based superalloys are the best choice.

Table on Materials Used in Metal Injection Molding (MIM)!

Choosing the Right Metal Injection Molding (MIM) Partner!

·        Experience in MIM

Choosing an experienced Metal Injection Molding (MIM) partner helps create strong parts. Exact molds are required for parts as small as 0.5 mm. Alloys, such as stainless steel or titanium, are used by experts.

Each metal adds strength. But experienced MIM makers also know and how to shape the items so they are durable. They are held to tolerances near ±0.1 mm using exact methods. MIM parts work and last longer with this level of experience.

·        Advanced Tooling Capabilities

Better parts, MIM partners with advanced tools. Fine mold use CAD/CAM to build. Tiny parts, as small as ±0.03mm accurate are kept in these molds. Now, more technologies allow for machines to catch errors fast, and mistakes are few. Metal Injection Molding (MIM) tools build parts with exact shapes every time. Less defects and higher quality parts are the result for every project.

·        Quality Certifications

ISO 9001 certification, for example, is meant to indicate just how much a MIM partner cares about quality. Every step is tested so parts will be strong. Strength checks are the kind of tests materials will go through. Good makers conduct many tests on the line to catch problems early (or before production).

This also makes sure that everything works right in the tough jobs. The strong parts that these industry need (automotive, medical, etc.) can work safely.

·        Design Collaboration

Designing with a MIM partner will improve parts. They allow them to pick small things such as wall thickness, going from 0.2 mm up to 5 mm. By making this choice parts stay strong.

Less happens when the designs fit with MIM tools. Parts happen quickly from idea to reality, through changes that happen quickly. It saves time and makes for parts that work well.

·        Production Capacity

Flexible setups can handle big or small order because MIM partners with. Batch sizes are 1,000,000 parts. Parts move quickly, so that orders are on time.

Metal Injection Molding (MIM) partners who scale up or down are helpful. They can keep steady production with sudden requests. Customers are happy when they can get the parts they need immediately when they need them.

The Advantages of Metal Injection Molding (MIM)!

• Complex Geometries: You can make complex shapes with Metal Injection Molding (MIM)! Shapes can have some curves, holes and also thin walls like 1.5mm.

The easy part is gears and electronic parts when you do in MIM. The main key in MIM is the creation of shapes with precise designs using metal powder and binders. Exact shape parts are taken out, meaning fewer extra steps.

• Material Efficiency: Metal Injection Molding (MIM) saves material! 99% of the metal is used – only 2% come off as waste. Parts with high strength are also shaped by special powders like stainless steel 316L. Metal that’s been left over goes back into use.

It saves industries money, such as cars and planes. MIM margins the satisfactory figment of metal for each oblanceolate.

• Precision Manufacturing: But with MIM, not only are parts precise, but even down to 0.1mm sizes (or small)! Thanks to MIM, accuracy is assured, within ±0.3%.

And it makes tiny pieces like 1.2mm pins very exact for medical tools. MIM uses molding and sintering to stay the same size and perfect for aerospace. It fits each part with no extra steps.

• Cost Reduction: MIM makes parts more cheaply! MIM can also lower costs by up to 30% below what CNC machining offers. For example, a 3cm part requires less labor and less time to make.

MIM also molds many times over, so tooling costs are saved. MIM is a cost saving way of doing big projects with many parts, such as electronics.

• High-Volume Consistency: Many parts are the same, every time, when you make them with MIM. With MIM, density and properties remain consistent on a piece-by-piece basis, so gears for watches are just right. MIM assures each unit be snug to snug sizes using metal powder in molds. It saves time and money because big batches can skip checks.

Cost-Efficiency of Metal Injection Molding (MIM)!

·        Reduced Labor Costs

Machines help make Metal Injection Molding (MIM) cheaper. Importantly, machines do more jobs, so you need fewer workers. For example, the deal for 100,000 parts can save you a lot of money.

P20 steel molds made in factories are used to make pieces fast. Workers only do 5 to 10 percent of the work. Making lots of parts quickly is what MIM is great at.

·        Minimal Secondary Operations

When molding is almost done, MIM parts are almost done. That is beneficial to you because you do not have to worry about extra cutting or fixing. For instance, it produces 20 percent less metal waste than other ways. That saves you half the cost because you skipped extra steps. The tolerances are ±0.1% making them perfect.

·        Automated Production

Factories use Metal Injection Molding (MIM) to make many parts fast. Some machines can make 100 parts every hour. Pressure and heat are watched by special sensors to make sure parts are good. You are fixing less. You don’t need workers to check every part, that saves time with MIM.

·        Low Material Waste

MIM wastes less metal. It also is about 80% less extra metal to save compared to other ways. MIM doesn’t use big metal blocks like cutting; it uses shapes made from metal powder.

Only 5% is wasted. The leftover powder is reused too. The process is good, because you can use it to save materials like titanium.

·        Short Lead Times

MIM makes parts fast. Parts can be ready in just 1 day. It takes only 2 – 4 weeks to finish big orders. MIM molds are set up quickly. You don’t wait long since the machines do most of the work. It’s great for making lots of parts quickly.

Conclusion

Metal Injection Molding (MIM) makes small parts strong and fast. With it you save material and money. MIM enables parts to be made just right. Want to learn more? To create great parts right now, visit JHMIM.