Metal injection Molding (MIM)
Metal Injection Molding (MIM) combines two well-established technologies: plastic injection molding and powder metallurgy. This process enables the production of precise and complex metal parts in large quantities, particularly with metals that cannot be die-cast, such as stainless steel and low alloy steels. Unlike machining, which involves removing material from a solid block to shape the desired part, MIM creates parts by molding metal powders into intricate forms.
Machining, though once a suitable alternative for creating complex components, can be less cost-effective depending on the size and complexity of the part being produced.
Machining
Machining is a traditional metalworking technique that involves progressively removing unwanted material from a raw workpiece to achieve the desired shape. This method is particularly useful for creating parts that cannot be made through die casting or investment casting. However, machining may not be the most cost-effective option for producing micro-sized or highly complex components.
Difference in Metal injection Molding (MIM) vs Machining
Metal Injection Molding (MIM) can produce finished components with mechanical properties comparable to those of machined parts. These MIM parts are commonly used in similar industries, including medical, electronics, industrial, and automotive sectors.
In certain cases, the surface appearance of MIM components closely resembles that of machined parts, making them suitable for applications where aesthetics and performance are critical.
Unique Geometry
Metal Injection Molding (MIM) offers exceptional capabilities for creating unique geometries and complex shapes. In contrast, machining often faces limitations in intricacy, flexibility, and design freedom, making it challenging to produce complex components.
As parts become more intricate, MIM becomes more cost-effective because the process can handle complexity without significantly increasing production time, unlike machining, which requires more time for complex parts.
Strength & Performance
While both MIM and machining produce strong components, MIM parts do not experience the stress or internal pressure that machining can introduce, which can lead to deformation or failure over time. MIM components are molded using standard molding machines and then placed in an oven, where the binder is carefully removed, resulting in a strong, solid part.
Mold Investment
In MIM, the complexity of a component is usually tied to the mold investment, meaning the mold or tool itself is complex. This results in a one-time upfront cost associated with the complexity of your MIM part. In contrast, with machining, increasing the complexity of a part adds to both the cost and the process time.
Material Scrap
The MIM process minimizes material waste, which is a significant advantage for customers. When sourcing machined parts, customers often pay for the material that becomes scrap. MIM, however, uses materials more efficiently, eliminating the cost associated with scrap material.
Capacity
MIM is more scalable in terms of production capacity. Increasing production, such as doubling the number of parts produced per week, requires more CNC machines when using machining. In contrast, MIM can accommodate increased production without needing significant additional equipment, making it a more scalable solution for high-volume production.
Tolerance
Metal injection molding (MIM) typically achieves tolerances ranging from ±2% to ±0.4%, with the final tolerances depending on the size and detail of specific features.
Due to the potential for shrinkage during the debinding and sintering processes, larger features often result in larger tolerances. Typical shrinkage rates in the sintering process range from 15% to 18%. Additionally, non-isotropic factors can affect expected tolerances, with gravity causing more shrinkage in the vertical direction, and drag forces leading to less shrinkage along the lengthwise direction.
Benefits of MIM
Utilizing the Metal Injection Molding (MIM) process offers several advantages, including:
Why Choose MIM Over Machining?
MIM can be a more cost-effective solution than machining, particularly for projects involving high volume and complex geometries. It excels in producing intricate, net shape components that do not require secondary machining, which can significantly reduce costs associated with secondary processes and overhead. Additionally, MIM’s ability to increase production rates makes it an ideal choice for large-scale manufacturing.
Why Choose Meta Build Industries for Metal Injection Molding?
Choose Meta Build Industries for your Metal Injection Molding needs because of our commitment to precision, quality, and efficiency.
We offer cutting-edge MIM technology that ensures high repeatability and superior cycle times, making us ideal for producing complex MIM parts, net shape components with minimal secondary operations.
Our experienced team provides comprehensive support, from design to production, ensuring your parts meet the highest standards. With a focus on innovation and customer satisfaction, Meta Build Industries delivers cost-effective solutions that optimize production rates and reduce overhead costs, making us the preferred partner for your MIM projects. Contact for MIM Parts Now.