Metal injection molding (MIM) is a hybrid technology which integrates the shaping capability of plastic injection molding and materials flexibility of conventional powder metallurgy. MIM is preferred for mass manufacturing of small, intricate geometric components of a variety of materials as it can achieve 95% to 98% of its wrought materials properties at a much lower cost.

The Technology

The initial step to MIM is material selection and preparation. Once the appropriate combinations of metal powder and plastic binders are blended and compounded, an injection moldable feedstock is produced.

Using an injection-molding machine, the parts produced are then subjected to a binder removal process. Depending upon the type of binder used, different methods of debinding are applied.

The parts, after debinding, then go through a sintering process to ensure the parts are of the right material composition, physical properties and correct geometry.

Advantages

• Greater design freedom
  With MIM, parts can be designed and manufactured without
  any design restrictions. In addition, almost all design changes
  are possible within the shortest development cycle and
  turnaround time.
• Miniaturization
  MIM technology is the best viable process for producing
  miniature parts economically.
• Complex and intricate shaped parts
  MIM is ideal for producing complex-shaped components
  as well as parts that require assembly or multiple steps to
  put together.
• High production requirements
  MIM is most beneficial in high volume production of small
  precision parts with complicated design geometry. The
  process lends itself to automation where high volumes
  and consistent quality are required.
  

The Applications

MIM technology has found increased applications in the commercial world – from home appliances to watches, automobiles to aerospace, and medical to orthodontics.

The Materials

Due to the flexibility of MIM technology, it is possible to customize material compositions according to the specific attributes required by the customers. Some of the compositions are stainless steels, low alloy steels, carbon steels, Ni-alloys, tool steels and tungsten alloys.

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