Metal Injection Molding
Encyclopedia
Metal injection molding (MIM) is a metalworking
process where finely-powdered metal is mixed with a measured amount of binder material to comprise a 'feedstock' capable of being handled by plastic
processing equipment through a process known as injection mold forming. The molding process allows complex parts to be shaped in a single operation and in high volume. End products are commonly component items used in various industries and applications. The nature of MIM feedstock flow is defined by a physics called rheology. Current equipment capability requires processing to stay limited to products that can be molded using typical volumes of 100 grams or less per "shot" into the mold. Rheology does allow this "shot" to be distributed into multiple cavities, thus becoming cost-effective for small, intricate, high-volume products which would otherwise be quite expensive to produce by alternate or classic methods. The variety of metals capable of implementation within MIM feedstock are referred to as powder metallurgy
, and these contain the same alloying constituents found in industry standards for common and exotic metal applications. Subsequent conditioning operations are performed on the molded shape, where the binder material is removed and the metal particles are coalesced into the desired state for the metal alloy.
; the name being condensed from the phrase 'particle materials technology'. Dr. Wiech later patented his process, and it was widely adopted for manufacturing use in the 1980s. Competing processes included pressed powder sintering
, investment casting
, and machining
.
MIM gained recognition throughout the 1990s as improvements to subsequent conditioning processes resulted in an end product that performs similar or better than those made through competing processes. MIM technology improved cost efficiency through high volume production to 'near-net-shape', negated costly, additional operations left unrealized in competing processes, and met rigid dimensional and metallurgical specifications.
The process steps involve combining metal powders with wax and plastic binders
to produce the 'feedstock' mix that is injected as a liquid into a hollow mold using plastic injection molding machines. The 'green part' is cooled and de-molded in the plastic molding machine. Next, a portion of the binder material is removed using solvent, thermal furnaces, catalytic process, or a combination of methods. The resulting, fragile and porous (2-4% "air") part, in a condition called "brown" stage, requires the metal to be condensed in a furnace process called Sintering
. MIM parts are sintered at temperatures nearly high enough to melt the entire metal part outright (up to 1450 degrees Celsius), at which the metal particle surfaces bind together to result in a final, 96-99% solid density. The end-product MIM metal has comparable mechanical and physical properties with parts made using classic metalworking methods, and MIM materials are compatible with the same subsequent metal conditioning treatments such as plating, passivating, annealing, carburizing, nitriding, and precipitation hardening.
, and automotive applications. Dimensional tolerances of +/-.003" per linear inch can be commonly held, and far closer restrictions on tolerance are possible with expert knowledge of molding and sintering. MIM can produce parts where it is difficult, or even impossible, to efficiently manufacture an item through other means of fabrication. Increased costs for traditional manufacturing methods inherent to part complexity, such as internal/external threads, miniaturization, or brand identity marking, typically do not increase the cost in a MIM operation due to the flexibility of injection molding.
There is a broad range of materials available when utilizing the MIM process. Traditional metalworking processes often involve a significant amount of material waste, which makes MIM a highly efficient option for the fabrication of complex components consisting of expensive/special alloys (Cobalt-chrome
, 17-4 PH Stainless Steel
). MIM is a viable option when extremely thin walls specifications (i.e. 0.008” thick) are required. Additionally, EMI shielding (Electromagnetic Interference
) requirements has presented unique challenges, which are being successfully attained through the utilization of specialty alloys (ASTM A753 Type 4).
Metalworking
Metalworking is the process of working with metals to create individual parts, assemblies, or large scale structures. The term covers a wide range of work from large ships and bridges to precise engine parts and delicate jewelry. It therefore includes a correspondingly wide range of skills,...
process where finely-powdered metal is mixed with a measured amount of binder material to comprise a 'feedstock' capable of being handled by plastic
Plastic
A plastic material is any of a wide range of synthetic or semi-synthetic organic solids used in the manufacture of industrial products. Plastics are typically polymers of high molecular mass, and may contain other substances to improve performance and/or reduce production costs...
processing equipment through a process known as injection mold forming. The molding process allows complex parts to be shaped in a single operation and in high volume. End products are commonly component items used in various industries and applications. The nature of MIM feedstock flow is defined by a physics called rheology. Current equipment capability requires processing to stay limited to products that can be molded using typical volumes of 100 grams or less per "shot" into the mold. Rheology does allow this "shot" to be distributed into multiple cavities, thus becoming cost-effective for small, intricate, high-volume products which would otherwise be quite expensive to produce by alternate or classic methods. The variety of metals capable of implementation within MIM feedstock are referred to as powder metallurgy
Powder metallurgy
Powder metallurgy is the process of blending fine powdered materials, pressing them into a desired shape , and then heating the compressed material in a controlled atmosphere to bond the material . The powder metallurgy process generally consists of four basic steps: powder manufacture, powder...
, and these contain the same alloying constituents found in industry standards for common and exotic metal applications. Subsequent conditioning operations are performed on the molded shape, where the binder material is removed and the metal particles are coalesced into the desired state for the metal alloy.
Process
An early developer of the process during the 1970s was Dr. Raymond E. Wiech Jr., who refined MIM technology as co-founder of a California company named ParmatechParmatech
Parmatech specializes in Metal Injection Molding and Ceramic Injection Molding , collectively known as Powder injection molding technology . Metal Injection Molding was invented and developed by Dr. Raymond E. Wiech Jr...
; the name being condensed from the phrase 'particle materials technology'. Dr. Wiech later patented his process, and it was widely adopted for manufacturing use in the 1980s. Competing processes included pressed powder sintering
Sintering
Sintering is a method used to create objects from powders. It is based on atomic diffusion. Diffusion occurs in any material above absolute zero, but it occurs much faster at higher temperatures. In most sintering processes, the powdered material is held in a mold and then heated to a temperature...
, investment casting
Investment casting
Investment casting is an industrial process based on and also called lost-wax casting, one of the oldest known metal-forming techniques. From 5,000 years ago, when beeswax formed the pattern, to today’s high-technology waxes, refractory materials and specialist alloys, the castings allow the...
, and machining
Machining
Conventional machining is a form of subtractive manufacturing, in which a collection of material-working processes utilizing power-driven machine tools, such as saws, lathes, milling machines, and drill presses, are used with a sharp cutting tool to physical remove material to achieve a desired...
.
MIM gained recognition throughout the 1990s as improvements to subsequent conditioning processes resulted in an end product that performs similar or better than those made through competing processes. MIM technology improved cost efficiency through high volume production to 'near-net-shape', negated costly, additional operations left unrealized in competing processes, and met rigid dimensional and metallurgical specifications.
The process steps involve combining metal powders with wax and plastic binders
Binder (material)
-See also:*Adhesive or Glue*Cement*Paint...
to produce the 'feedstock' mix that is injected as a liquid into a hollow mold using plastic injection molding machines. The 'green part' is cooled and de-molded in the plastic molding machine. Next, a portion of the binder material is removed using solvent, thermal furnaces, catalytic process, or a combination of methods. The resulting, fragile and porous (2-4% "air") part, in a condition called "brown" stage, requires the metal to be condensed in a furnace process called Sintering
Sintering
Sintering is a method used to create objects from powders. It is based on atomic diffusion. Diffusion occurs in any material above absolute zero, but it occurs much faster at higher temperatures. In most sintering processes, the powdered material is held in a mold and then heated to a temperature...
. MIM parts are sintered at temperatures nearly high enough to melt the entire metal part outright (up to 1450 degrees Celsius), at which the metal particle surfaces bind together to result in a final, 96-99% solid density. The end-product MIM metal has comparable mechanical and physical properties with parts made using classic metalworking methods, and MIM materials are compatible with the same subsequent metal conditioning treatments such as plating, passivating, annealing, carburizing, nitriding, and precipitation hardening.
Applications
The window of economic advantage in metal injection molded parts lies in complexity and volume for small-size parts. MIM materials are comparable to metal formed by competing methods, and final products are used in a broad range of industrial, commercial, medical, dental, firearms, aerospaceAerospace
Aerospace comprises the atmosphere of Earth and surrounding space. Typically the term is used to refer to the industry that researches, designs, manufactures, operates, and maintains vehicles moving through air and space...
, and automotive applications. Dimensional tolerances of +/-.003" per linear inch can be commonly held, and far closer restrictions on tolerance are possible with expert knowledge of molding and sintering. MIM can produce parts where it is difficult, or even impossible, to efficiently manufacture an item through other means of fabrication. Increased costs for traditional manufacturing methods inherent to part complexity, such as internal/external threads, miniaturization, or brand identity marking, typically do not increase the cost in a MIM operation due to the flexibility of injection molding.
There is a broad range of materials available when utilizing the MIM process. Traditional metalworking processes often involve a significant amount of material waste, which makes MIM a highly efficient option for the fabrication of complex components consisting of expensive/special alloys (Cobalt-chrome
Cobalt-chrome
Cobalt-chrome is a metal alloy of cobalt and chromium. Cobalt-chrome has a very high specific strength and is commonly used in gas turbines, dental implants, and orthopaedic implants....
, 17-4 PH Stainless Steel
Stainless steel
In metallurgy, stainless steel, also known as inox steel or inox from French "inoxydable", is defined as a steel alloy with a minimum of 10.5 or 11% chromium content by mass....
). MIM is a viable option when extremely thin walls specifications (i.e. 0.008” thick) are required. Additionally, EMI shielding (Electromagnetic Interference
Electromagnetic interference
Electromagnetic interference is disturbance that affects an electrical circuit due to either electromagnetic induction or electromagnetic radiation emitted from an external source. The disturbance may interrupt, obstruct, or otherwise degrade or limit the effective performance of the circuit...
) requirements has presented unique challenges, which are being successfully attained through the utilization of specialty alloys (ASTM A753 Type 4).