What is Metal Injection Molding?
Metal injection molding (MIM) is an innovative manufacturing process that combines the benefits of traditional plastic injection molding with the strength and durability of metal parts. MIM parts are strong and can be made with very tight tolerances. They can also be made in complex shapes that would be difficult to produce with other manufacturing methods. As an efficient and cost-effective alternative to conventional metalworking processes, such as die casting and machining, MIM helps create parts in extensive shapes and sizes with intricate detail and complexity. Therefore, the process is widely used in the production of intricate parts with tight tolerances and complex features.
Step 1: Powder Mixing First, a blend of powdered metal and a binder, such as wax or a polymer, is mixed in a blender. The proportions of the metal powder and binder must be precise in order to create the desired parts. The binding agent used in the process can affect the final properties of the part, and the metal powder can be difficult to uniformity.
Step 2: Feedstock Preparation The powder blend from the mixer is then fed into a machine, such as an extruder or injection molding machine, where it is blended with additional binders and vacuum degassed for a uniform and homogeneous feedstock.
Step 3: Injection molding The feedstock is then injected under pressure into a mold cavity where it takes the shape of the cavity. The high pressure causes the metal powder and binder mix to form a solid part.
Step 4: Debinding The formed part is then placed in a debinding chamber where the binder is removed using solvents or other agents, resulting in a green part with a porous structure.
Step 5: Sintering The green part is then heated in an oven in a process called sintering. The heat causes the particles in the powdered metal to bond together and fill any voids. In sintering, temperatures are generally much lower than with traditional metal-forming processes, resulting in a fully-dense part with high strength
Step 6: Final Finishing After sintering, the part is ready for final finishing. This could involve processes such as machining, surface cleaning, and polishing to achieve the desired level of quality.
The Metal injection molding process, combined with its wide range of alloys and near-net shapes, make MIM extremely versatile and capable of producing virtually any small-to-medium-sized metal parts with consistent quality and soft material properties.
Difference between Metal Injection molding and Powder Metallurgy
| Used to create parts by using powdered metal as feedstock in the mold. |
| Suitable for creating small, intricate parts with tight tolerance |
| Relatively quick and process can be automated |
| High degree of accuracy and reliable |
| Ideal for high speed and large volume of production with intricate designs |
| Similar to MIM, but instead of using a mold, the metal powder is compressed into the desired shape. |
| Suited for creating large, complex parts with less tolerance range |
| Less Expensive |
| Simple and accurate |
| Suitable for smaller batches of precision applications |
MATERIALS
Zastata uses a variety of materials for Metal Injection molding process to produce various types of products. Each material has its own advantages and disadvantages. The kind of material used to mould the part mainly depends on its application and utilization.
These metals are chosen for their resistance to wear and corrosion, as well as their strength and hardness. They are
Ferrous Alloys – steels, stainless steels, tool steels, iron-nickel magnetic alloys, Thermoplastics are the most used materials in injection moulding because they are easy to use and versatile.
Stainless Steel – Used for its ability to corrosion resistance, durability, withstand high temperatures, easy to recycle.
Tool Steel – Due to its high carbon content, it can be used in high temperature applications. Can be hardened to increase its wear resistance and toughness.
Low Steel Alloy – It is made by mixing other elements with steel, for exhibiting some desirable properties. Some of the chemical compositions are nickel steel, nickel chromium steel, nickel molybdenum steel,etc.
Non – Ferrous Alloys – Non- ferrous materials like Aluminium, Zinc, Brass, Tombak, Copper, and their respective alloys are also in the MIM for their excellent chemical properties.
Other commonly used metals include Inconel, Kovar, Tungsten Alloys and x-750, all of which exhibit excellent heat and corrosion resistance. Metals with higher melting points or that are difficult to cast, such as alloys of titanium, cobalt, and nickel, can also be sintered using MIM.
Zastata also performs number of inspection methods used in plastic injection moulding, each with their own advantages and disadvantages.
There are a variety of inspection methods that can be used to ensure the quality of MIM parts.
- Visual inspection is typically used to check for surface defects, such as cracks, voids, or inclusions.
- X-ray inspection can be used to check for internal defects, such as porosity or voids.
- Ultrasonic inspection can be used to detect defects that are not visible to the naked eye, such as voids, inclusions, or porosity. This method is particularly useful for checking thin-walled parts.
- Magnetic particle inspection can be used to detect surface and subsurface defects in ferrous metals. This method is typically used for checking for cracks, inclusions, or voids.
- Eddy current inspection can be used to detect surface and subsurface defects in non-ferrous metals. This method is typically used for checking for cracks, inclusions, or voids.
- Thermographic inspection can be used to detect differences in the thermal conductivity of a material, which can be an indication of a defect. This method is particularly useful for detecting cracks, voids, or inclusions in metals.
By using a combination of these methods, it is possible to detect a wide range of defects, ensuring that parts meet the highest standards of quality prior to use. Zastata can help them produce reliable components for a variety of industries.
Zastata also performs number of inspection methods used in plastic injection moulding, each with their own advantages and disadvantages.
Quality Documentation
Zastata has good understanding and experience with Quality documentation like:
APQP – Advanced Product Quality Planning
FMEA – Failure Mode Effective Analysis
PPAP Level 3 – Production Part Approval Process
SPC – Statistical Process Control
MSA – Measurement System Analysis
Quality Certifications
We work with manufacturers who hold certifications like:
ISO 9001:2015 (Quality Management System)
ISO 14001:2015 (Environmental Management System)
ISO 45001:2018 (OH & SMS)
AS9100 Rev C (Aviation, Space and Defence)
ISO13485:2016 (Medical Devices)
IATF16949:2016 (Automotive Quality Management System)
OTHER TYPES OF METAL FABRICATION
Whilst Pressure die casting is widely used casting method for high volume production, there are other casting methods which have their merits
OUR MANUFACTURER LOCATIONS
Over the years, Zastata has audited and worked with various die casting manufacturer across India for various casting types. Our pressure die casting company are selected and retained based on their quarterly quality performance on Cost, Delivery, Quality, Communication, Innovation and flexibility.
COUNTRIES WE EXPORT
Over the years, Zastata has audited and worked with various die casting manufacturer across India for various casting types. Our pressure die casting company are selected and retained based on their quarterly quality performance on Cost, Delivery, Quality, Communication, Innovation and flexibility.
UK
USA
AUS
Denmark
Germany
Canada
France
China
INDUSTRIES WE SERVE
Advantages:
- Ability to produce strong, complex parts with tight tolerances.
- MIM parts are also less expensive than parts made with other methods, such as machining or investment casting.
- Cost effective, more versatile, and repeatable, making it an ideal choice for mass production for various shapes and size.
- Products made using plastic injection molding are often very strong and durable.
- Smooth Surface finish.
Applications
The MIM process is typically used for small, intricate parts such as golf club heads and medical implants. However, it can also be used to produce larger parts such as car body panels.
Common applications for MIM parts include Bio-medical devices, automotive parts, and firearms components. It has been used to produce a wide range of components for fields as varied as aerospace, electronics, and consumer products.
- In the biomedical field, are using MIM to produce components used in jaw and hip joint replacements and surgically implanted stents.
- Areas like automotive suspension, engines, powertrain, stabilizers, turbochargers, and wheels, MIM is proving to be a highly cost-competitive alternative.
- In the aerospace industry, metal injection moulding is producing components for a wide range of aircrafts, including both commercial and military.
- Components like rocket engine fuel nozzles, jet engines nozzles, thrust reversers, instrument panels, and other subsystems.
Overall, MIM offers unique advantages over traditional manufacturing processes due to its cost-effectiveness and its ability to create intricate parts with tight tolerances. By carefully manipulating the composition of the powdered metal and binders, MIM can save time and money while still producing complex parts with complex features.
Zastata ensures that parts manufactured out of metal Injection moulding process meet the drawing specifications without any deviations and ensures smooth transitioning from samples to production stage of the supply chain process.
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