Benefits of Using Metal Injection Molding Technology

Metal Injection Molding is a modern manufacturing process that involves mixing metal powder and binder, injecting it into a mould and making metal parts by degreasing or sintering. The advantages of MIM are seen in many dimensions, such as the processing of complex structures, material selection, cost control, and production efficiency. Here are some of the benefits.

High-precision and complex structure capability

Realization of complex geometric forms:

The machine can produce complex 3-dimensional structures, which are impossible to achieve with conventional processing methods (such a cutting and casting), including parts with internal threads and holes, thin walls and hollows, as well as multiple steps.

MIM can be used to mold small connectors and forceps for minimally invasive surgery in medical devices in one step.

Surface quality and precision:

The surface roughness can be Ra 1.6-3.2mm and the accuracy of dimensions can reach +0.1 %~+-0.5%. This reduces or eliminates secondary processing, such as polishing and grinder.

Performance close to that of forgings, wide material adaptability

Use of different metals and alloys

This is applicable to powder materials like stainless steel, titanium, tungsten, cobalt chrome, aluminum, refractory metals, composite materials, molybdenum and tantalum.

Applications: titanium alloys in aerospace, cobalt chrome alloy implants in medical fields.

Outstanding mechanical properties

Sintered parts have a density between 95% and 99% and their strength, hardness and corrosion resistance are comparable to forgings. They also perform better than powder metal parts.

Cost-effectiveness and efficiency of batch production

Automated batch manufacturing:

The injection molding process allows for high-speed, automated production. A single part can be produced in a short time (a few minutes to over ten minutes), making it ideal for batch production with annual outputs ranging from tens to millions of parts.

Low cost and high material utilization:

The unit cost of batch production is much lower than that of precision casting or machining, where a lot of material must be removed.

Comparatively, traditional cutting processes can waste up to 50% of the materials used in manufacturing small and complex components, while MIM technology reduces material costs by a significant amount.

Miniaturization and micro manufacturing: advantages

Production of micro-parts at large scale:

The precision and consistency of the process is far superior to traditional processing. This includes parts with a weight range from 0.1 to 200 grams, and especially small parts weighing 0.5 to 50 g (such as watch accessories and electronic components).

Structural Integration:

Reduce assembly time by integrating multiple parts into one MIM part. MIM technology can reduce assembly costs by combining multiple parts, such as the sensor bracket of the airbag in a car.

Sustainability and environmental protection

Green Production Process:

Sintering is more eco-friendly than electroplating and casting (metal melting).

Recyclability:

The concept of sustainable manufacturing is based on the recycling and reuse of unsintered waste and a low loss in powder material.

Applications in industry

3C Electronics and Communications: Mobile phone card trays; camera brackets; 5G base station components for heat dissipation.

Medical equipment: orthopedic implants, dental restorations and surgical instruments.

Automotive and aviation: turbochargers blades, fuel injector system parts, aircraft engines seals

Consumer electronics: Watch cases, jewelry accessories and precision parts for sports equipment.

Metal injection molding technology overcomes the limitations of traditional metal processes in complex structures, minimization, and mass-production through “injection molding + powder metallurgy” and is especially suitable for high-end manufacturing situations with comprehensive requirements regarding precision, performance, and cost. The application scope of powder preparation equipment and technology is expanding.