Powder Metallurgy vs Metal Injection Mold

Powder Metallurgy vs Metal Injection Mold

50-100pm Powdered Particle Size 2-15pm
92% (Max) Relative Density >95-99%
2-20mm Wall Thickness 0.30 -10mm
Medium Component Complexity High
1-1,000g Weight 0.01-200g
0.1-2.0% Tolerance 0.3-0.5%

Choosing Between Powder Metal and MIM:

  1. MIM is excellent for complex shapes 
  2. MIM requires high temperatures to sinter
  3. MIM parts go through approximately 25% shrinkage
  4. MIM is expensive

Powder Metallurgy Basics:

  1. Begin with blending or mixing specific types of metal powders and lubricants.
  2. Place the mix in a die to create a certain shape.
  3. Use a press to compact the metal powder tightly.
  4. Sinter the compressed part in a furnace to form metallurgical bonds in the metal powder.

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MIM Products

MIM Products:

Metal Injection Molding parts are used through the medical, dental, aerospace, defense, automotive, agricultural business equipment, computer hardware, bio-medical and armaments.

MIM Products application:

  • Wheel Chairs
  • Hospital Beds
  • Analyzing Equipment
  • Prosthetics
  • X-ray Machines
  • Hospital Automation
  • Pacemakers
  • Surgical Instruments and Equipment
  • Fiber Optic Connectors
  • Filter Components
  • Heat Sinks
  • Microwave Equipment
  • Mobile Phones
  • Solenoids
  • Micro-Switches
  • Standoffs
  • Connectors
  • Distribution Frames
  • Switching Components
  • Drives
  • Controls
  • Material Handling
  • Robotics
  • Scales
  • Conveyers
  • Speed Reduction
  • Clutch Drives
  • Gear Drives
  • Accessories
  • Ratchets
  • Drill Chucks
  • Motors
  • Lock Mechanisms
  • Padlocks
  • Panic Bar Components
  • Plumbing Components
  • Door Closure Systems
  • Attachments and Accessories
  • Garage Doors
  • Spraying and Paint Systems
  • Precision Orifices
  • Cargo Latches

Common materials: 

  • Stainless Steels
  • Low Allow Steels
  • Superalloys (Inconel, Hastelloy X)
  • High-density Alloys (Tungsten – Iron – Nickel)
  • Controlled Expansion Alloys (Alloy 42, Kovar)
  • Soft Magnetic Alloys

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MIM (Metal Injection Molding)

MIM (Metal Injection Molding) :

MIM (Metal Injection Molding) is a metalworking process in which finely-powdered metal is mixed with binder material to create a “feedstock” that is then shaped and solidified using injection molding.

Plus, MIM is be used  across different industries including your cell phone.

Introduction of MIM:

  • The molding process allows high volume, complex parts to be shaped in a single step.
  • After molding, the part undergoes conditioning operations to remove the binder (rebinding) and densify the powders. Finished products are small components used in many industries and applications.
  • MIM has used to manufacture millions of parts for medical device including powered device drive chains, end effectors, connectors, and other applications. for over 20 years.

Process of MIM: 

1st step: Very fine metal powders are combined with thermoplastic and wax binders in a precise recipe. A proprietary compounding process creates a homogenous pelletized feedstock that can be injection molded just like plastic. This achieves ultra-high density and close tolerances over high-production runs.

2nd Step: Unlike standard powder metallurgy, which can achieve only 80-90% of theoretical density, MIM results in 95-100%. This means we can achieve close tolerances and reduce costs by producing small, complex parts over high production runs.

3rd Step: The feedstock is heated and injected into a mold cavity under high pressure. This enables us to produce extremely complex shapes and allows for shorter cycle times.

4th Step: Once molded, the component is referred to as a “green” part. Its geometry is identical to the finished piece but is about 20% larger to allow for shrinkage during the final sintering phase.

5th Step: Binder removal (rebinding) involves a controlled process to remove most of the binders and prepare the part for the final step – sintering.

6th Step: Once rebinding is complete, the component is referred to as “brown.”

7th Step: The brown part is held together by a small amount of the binder, and is very fragile.

8th Step: Sintering eliminates the remaining binder and gives the part its final geometry and strength.

9th Step: During sintering, the part is subjected to temperatures near the melting point of the material.

Advantage of MIM:

Metal Injection Molding have excellent strength, hardened and welded  and heat treated like any other wrought material.

The advantage 2H1U:

  • High-Precision
  • High-production rate
  • Unlimited


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