Metal Injection Molding
Metal injection moulding (MIM) is delivering the three-dimensional shape capability of plastic injection moulding combined with the performance of alloy steels, stainless steels and high temperature alloys. MIM is uniquely positioned to solve extreme product challenges, enabling the production of complex, high-density components with minimal material waste.
Overview
Metal Injection Moulding (MIM) is an innovative technology that combines the design flexibility of plastic injection molding with the material performance of wrought metals. This technology enables the production of dense, durable, and lightweight components while reducing material waste and overall production costs. MIM is particularly advantageous for complex geometries, offering exceptional strength and precision for demanding applications.
Metal Injection Molding (MIM) Process
Metal powders are blended with binders and formed into a feedstock, which is then injection moulded into complex shapes with high accuracy. After moulding, the parts undergo debinding and sintering in a controlled environment, achieving high density and near-wrought material properties. Secondary treatments such as heat treatment, surface coating, or machining further enhance durability and performance to meet exacting standards.
Feedstock Preparation
The MIM process begins with the creation of feedstock, a carefully blended mixture of metal powders and binding agents.
- Powder Blending: Metal powders are selected and blended to achieve the required material properties.
- Granulation: The blended feedstock is processed into granular pellets to ensure consistency in injection moulding.
- Process Control: Engineers apply precise controls to maintain powder characteristics and material integrity.
Benefit: This stage ensures uniform material distribution, supporting the production of complex, high-performance components.
Key Benefits of MIM Technology
- Complex Geometries: MIM excels in producing parts with intricate shapes, thin walls, and internal features that would be challenging or cost-prohibitive to produce using traditional manufacturing methods.
- Material Efficiency: The near-net-shape production process reduces material waste, making it highly cost-effective for high-volume production.
- Consistency: MIM ensures uniformity and precision across large production runs, guaranteeing high-quality parts with minimal variation.
- Superior Mechanical Properties: MIM parts have mechanical properties comparable to solid wrought materials, ensuring strength and durability.
- Cost-Effectiveness: MIM significantly reduces production costs by eliminating the need for costly machining steps, making it ideal for high-volume production of precision parts.
Applications of MIM
MIM is an ideal solution for industries requiring complex, high-performance components. Some of the typical applications include:
- Automotive: Small engine components, transmission parts, and structural elements.
- Aerospace: Lightweight, high-strength parts for aircraft and satellite systems.
- Medical Devices: Surgical instruments, implants, and diagnostic equipment.
- Consumer Products: Watches, mobile phones, and home appliances.
- Industrial: Tools, hardware, and precision equipment.
Driving Sustainability with Advanced Powder Solutions
Powder Metallurgy (PM) delivers significant environmental benefits by reducing material waste, energy usage, and emissions through efficient, near-net-shape manufacturing processes. By recycling and reusing up to 100% of metal powders, PM conserves resources and supports sustainable production. At GKN Powder Metallurgy, sustainability is embedded in our operations, enabling manufacturers to reduce environmental impact, improve material efficiency, and achieve cost-effective solutions across diverse applications.