This article focuses on the various benefits of metal injection molding. This process combines several different operations into a single process. The process reduces waste and toxic emissions, and is especially efficient when producing intricate shapes and micro-sized parts. It is also cost-effective, and is a viable alternative for high-volume production. Learn more about metal injection molding and what makes it so popular in the manufacturing industry. Also read about the Mechanical Properties of metals and how this process differs from other processes.
Process
Metal injection molding is a highly effective manufacturing process for producing intricate, small precision metal parts. This process is well suited for high-volume production of geometrically complex parts, and offers design freedom comparable to that found in plastic injection molding and investment casting processes. It is also capable of producing parts in a wide range of alloy compositions, including medical-grade stainless steels. In addition, it can form net-shaped parts directly. Depending on the type of metal alloy, the process can be highly customized and offer a high degree of design freedom.
The MIM process produces single material parts with densities of 93 to 99% of their theoretical density. This level of density cannot be achieved using conventional powder metallurgy compaction techniques, and can only be achieved with high-volume production. It is also limited by the complex geometry. However, MIM is increasingly gaining popularity among manufacturers of high-density metal components. Here are some key advantages of metal injection molding:
Materials
Polyamides are a popular choice among plastic material manufacturers. These plastics are tough, durable, and have low coefficients of friction. They are also good for a variety of applications, including conveyor belts, pulley wheels, and eyeglass frames. The downside to POM plastic is that it is prone to shrinkage and insufficient filling. However, these plastics are also excellent for electrical and electronic components, as well as medical equipment.
The process of metal injection molding is similar to that used for plastic injection molding. The powdered metal feedstock is processed at high temperatures and pressure to form high-performance parts. It is ideal for parts with complex shapes, as well as for applications that require excellent strength, ductility, and magnetic response. For this reason, MIM is an excellent choice for medical devices, such as pacemakers and surgical instruments. Metal injection molding has a range of applications, from aerospace and hardware to watch cases and automotive parts.
Mechanical properties
The mechanical properties of metal injection molds are primarily determined by the type of metal used for the component. Stainless steel, for example, is an excellent choice for many medical applications due to its strength, ductility, and corrosion resistance. Stainless steel is also easy to sterilize and comes in different grades, including martensitic and austenitic. The martensitic type is more desirable for applications requiring a high degree of wear resistance and sharp cutting edges. Surgical instruments are often produced in high volumes using machining processes, and the process is ideal for such components.
In addition to producing complex and smaller parts, metal injection molding is a viable option for a variety of medical applications. For example, medical devices, such as laparoscopic instruments, require a variety of metal parts to function properly. Advanced Powder Products’ 3D metal printing technology, PrintAlloy(r), enables companies to achieve a fast turnaround for metal components. Because the technology is based on additive manufacturing, this process requires no upfront tooling investment, enabling users to conduct functional testing of components before ordering them.
Cost
In today’s economy, cost is the number one concern for manufacturers. The cost of metal injection molding is one such concern. In many ways, this process has many advantages. Compared to traditional machining, metal injection molding can be a cheaper option for mass production. Unlike traditional machining, metal injection molding can also be used for the production of large thin-wall parts. However, it is important to keep in mind that metal injection molding is not a replacement for casting.
The industry is growing fast, thanks in part to federal government initiatives to promote the medical industry. One of these initiatives is the increased government funding for medical technology. This will undoubtedly spur the growth of the metal injection molding materials market. However, the high cost of metal injection molding materials will limit its growth. For this reason, it is necessary to understand what factors will determine the cost of metal injection molding. By defining the key factors, this industry will be able to overcome this bottleneck and become a global player.
Applications
The applications of Metal Injection molding are wide-ranging. The electronics industry is a major consumer of MIM parts, accounting for more than half of the market in Asia. This technology is ideal for the production of highly complex components, such as valve rocker arms. In addition to providing superior performance, it is also much cheaper than machining. The following are examples of industries that benefit from the technology. Automotive – automobile parts include fuel injectors and turbochargers.
Industrial – In addition to the aerospace, medical and hardware industries, metal injection molding is also used for low-volume stainless steel parts. The process uses a combination of plastic binders and metal powder to achieve an incredibly high degree of structural integrity and flexibility. The advantages of this technology are numerous, and they are becoming more common in several industries. To learn more about these applications, watch Proto Labs’ representatives. There are also many benefits to metal injection molding.
