Metal Injection Molding
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What is Metal Injection Molding?
The metal Injection Molding process combines the design flexibility of Plastic Injection Molding with the strength and durability of wrought metals for complex shaped part geometries. The MIM process is typically divided into three categories Molding, De-binding, and Sintering.
MIM process is particularly well-suited for streamlining the manufacture of products in large quantities or those with intricate designs.
Metal Injection Molding Process includes Three steps
- Molding
- Debinding
- Sintering
How MIM Works?
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Metal Injection Molding (MIM) process & steps
Molding Process
Injection Molding operates with the same machinery and approach as Plastic Injection Molding. In this process, pelletized feedstock is placed into an injection molding machine, where it’s heated and then injected under high pressure into a mold cavity.
This forms a « green part » that is allowed to cool and is subsequently ejected from the mold, allowing the cycle to restart. Because only the binders are meant to melt (serving to transport the metal powders), the process occurs at around 200°C.
The molds can feature multiple cavities to enhance production rates. To account for the shrinkage occurring during sintering, the mold cavity is designed about 20% larger. This shrinkage rate is accurately predetermined for each type of material used.
Debinding Process
Following Injection Molding, the formed part advances to the subsequent phase known as De-binding process. This step involves eliminating the binder materials from the molded Metal Injection Molding (MIM) part.
Typically conducted in multiple stages, the process removes the majority of the binder prior to sintering, retaining just enough to facilitate the handling of the parts into the sintering furnace.
The removal of the binder is achieved through various techniques, with solvent extraction being among the most common. Post-debinding, the part becomes semi-porous, which aids in the escape of the residual binder during the sintering phase.
Sintering Process
The parts are positioned on ceramic setters, which are then placed into a sintering furnace capable of high temperatures and controlled atmospheres. In this furnace, the brown parts are gradually heated in a protective environment to eliminate any remaining binders.
After the binders have been vaporized, the temperature of the metal parts is increased to a level where the spaces between particles disappear as the particles themselves begin to fuse together. This causes the part to shrink uniformly to its intended dimensions, resulting in a dense, solid form.
The density of the sintered parts typically exceeds 97% of the theoretical density for most materials. Such a high density endows the finished product with properties akin to those of wrought materials.
Features Of MIM process
Strength and Tensile Properties
It is advisable to use stainless steel for components that require exceptional strength and resistance to corrosion.
Durability and Strength
Low-alloy steel is highly effective in producing extremely hard components, making it an ideal choice for mechanically demanding applications.
Fatigue Resistance and Toughness
Heat-treated steel is an excellent choice for components that demand both high fatigue strength and toughness.
Meta Build Industries - Metal Injection Molding Manufacturer
Meta Build Industries is a leading global supplier specializing in Metal Injection Molding parts, catering high volume to a diverse array of industries around the world.
We are dedicated to excellence and innovation. We use MIM technology to create parts with complex shapes and great mechanical properties.
Our products are pivotal in driving advancements and efficiency across sectors including aerospace, automotive, medical devices, consumer electronics, and defense.
Our advanced product manufacturing capabilities include multi-cavity tooling. This helps us achieve high production rates at cost effective. We do this without losing precision or quality.
Our strict quality control measures ensure that every part we deliver meets our client’s high standards. This provides excellent dimensional tolerance and a variety of geometric features.