MIM (Metal Injection Molding)

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.