MIM produces near-net shaped metal parts, eliminating secondary operations and saving costs. Parts can be designed with recessed features, threads and undercuts.
For best results, designs should be engineered to allow for uniform wall thickness and avoid geometries that overhang, as this may cause set issues during sintering. Also, ejector pin marks should be located in areas not visible when the part is assembled.
Flexibility in Piece Geometry
MIM processing is well-suited for producing components with complex geometries in annual volumes of 10,000 pieces or more and finished part weights under 100 g. However, dimensional tolerances can become more challenging with larger component sizes. For components with highly precise dimensions, an alternative production process such as traditional casting or forging may be needed.
MIM parts are fabricated from a variety of metals, including stainless steels, titanium, tungsten, and nickel alloys. These materials offer specific performance advantages, such as strength-to-weight ratios and corrosion resistance, that help meet the requirements of your application.
MIM’s versatile process allows designers to incorporate features like threads, holes, and engravings directly into the park design. This reduces the need for post-processing steps and can help you save time and money.
Strong Dimensional Stability
The MIM process allows for complex geometries and tight tolerances that can be difficult or impossible to produce using traditional machining or casting methods. This versatility is especially useful for aerospace, medical, and dental applications where precision and quality are paramount.
A highly resilient mold fabricated from hardened tool steel ensures that the part will maintain its geometry and dimensions throughout the entire manufacturing process. This strong dimensional stability can eliminate the need for secondary operations, as well as reduce production time and costs.
The MIM process also offers the flexibility to use a wide range of metal alloys, including titanium, tungsten, and nickel alloys. These materials are particularly useful for producing aerospace and medical components that require high strength, wear resistance, or corrosion protection. The efficient utilization of metal during MIM manufacturing can further lower the overall cost of production by reducing material waste. To confirm the integrity of MIM parts, metallographic analysis is often used. This technique examines polished segments of a part under an electron microscope to determine the grain size distribution and surface defects, among other properties.
High Precision
MIM parts are very accurate, making them well-suited for precision products that require tight tolerances and consistent dimensions. In fact, the accuracy of MIM parts has led to the use of these components in many medical applications, including minimally invasive surgical instruments that need higher degrees of articulation and strong corrosion resistance.
MIM is also the perfect production process for a variety of engine and power-generation components that must withstand high temperatures and pressures. In addition, MIM allows for the use of high-performance superalloys that provide excellent strength and wear resistance.
MIM is also ideal for producing magnetic devices that require soft magnetic alloys, such as nickel-iron and iron-silicone alloys. These materials offer low coercivity and high permeability, making them ideal for electromagnetic devices like transformers and inductors.
Cost-Effective
MIM is a cost-effective manufacturing process that can produce parts that are difficult or impossible to manufacture with traditional methods. The process eliminates the need for multiple machining and assembly steps, which reduces labor costs. MIM also produces components in a net shape, minimizing material waste.
In addition, the MIM process can accommodate a wide variety of metals, including titanium alloys, nickel alloys, and iron-nickel alloys. This allows engineers to develop designs with the specific strength, corrosion resistance, and other characteristics they require for their applications.
For example, the ongoing trend toward miniaturization in consumer electronics requires intricate, Nitinol (a nickel-titanium alloy)-based components that possess shape memory properties. MIM can produce these types of components to tight tolerances, enabling the creation of smaller, more powerful devices with better performance and user experience. Moreover, the process can be cost-effective for high volume production, as upfront tooling costs can be recovered within the first year due to part-price savings.
