Metal Injection Molding

What is Metal Injection Molding?

Metal Injection Molding (MIM) combines the technologies of

thermoplastic injection molding and powder metallurgy to
produce complex-shaped, high density, high performance
metal parts. Best applied to small parts (typically less than
100 grams), the MIM process offers lower cost solutions for
numerous applications compared to machining or
investment casting, and improved mechanical properties
compared to plastic injection molding or zinc die casting.

Since the commercial beginnings of the Metal Injection

Molding process in the mid-1970’s, the technology has
matured and gained acceptance in numerous industries,
including Automotive Systems, Medical and Dental
Instruments, Orthodontics, Firearms, Hardware and Lock
Components, and Computer and Electrical applications.

Benefits of the Metal Injection Molding Process

The benefits of the MIM process are best realized by

considering the MIM manufacturing process during the initial
design stage of the parts or assembly. The primary benefits
include:

• Design Freedom - MIM offers design flexibility similar

to plastic injection molding. Geometrically complex
parts that cannot be produced using the conventional
powder metal processes without secondary machining
are possible using the MIM process.
• Enhanced Details - MIM provides intricate features
such as dovetails, slots, undercuts, threads, and
complex curved surfaces. MIM can produce cylindrical
parts with greater length-to-diameter ratios.
 • Reduced Assemblies – The MIM process can be used
to combine two or more simpler shapes into a single,
more complex component to minimize assembly costs.
• Reduced Waste/Machining - MIM's capability to
provide net shape components eliminates many
secondary machining operations.
• Improved Properties - MIM parts are typically 95% to
98% dense, approaching wrought material properties.
MIM parts achieve greater strength, better corrosion
resistance, and improved magnetic properties when
compared to conventional powder metallurgy
processes.

Customers requiring mechanical properties exceeding those

available with plastic injection molded or die cast materials
are turning to MIM. Metal Injection Molding also provides a
cost-effective, automated alternative to the labor-intensive
investment casting process. With highly complex geometries
available, MIM is an effective alternative to complex
machined components or intricate assemblies.

MIM excels at producing small, complex components that

require thin, uniform cross sections (up to .250 inch). Thicker
sections are typically limited by the high cost of the raw
material, the difficulties involved in molding defect-free thick
sections, and the ability to remove the binders effectively
from the molded parts.

The economics of the MIM process favors higher annual part

volumes. Although MIM can be a cost-effective solution for
small, complex parts at lower volumes, the cost of molding
tools discourages lower volume applications.

Limitations of the MIM Process

• Size – The economical part size is typically limited to

less than 100 grams due to the cost of the fine metal
powders used for MIM parts.
• Section Thickness – The maximum section thickness
is generally kept to less than 0.25 inch to effectively
 remove the thermoplastic binder from the part without
damage, and to control distortion during sintering,
• Tolerances – Typically +/- 0.5 percent, down to +/-
0.001 inch (0.025 mm) for very small dimensions.
Tighter tolerances require secondary machining or
grinding operations.
• Production Volume – Tooling costs generally limit the
economic annual production volume to greater than
10,000 parts (with exceptions for very expensive parts).

Why SSI-Sintered Specialties?

• Stainless Steel - Leaders in Powder Metal stainless

steel manufacturing.
• Sintering Capability – Vacuum, Ceramic Belt, and
Pusher style furnaces for high temperature batch and
continuous sintering.
• Quality Systems – Experienced, high volume
automotive industry supplier with ISO 9000 and TS
16949 certifications.

MIM Applications

• Automotive Systems - Steering Columns (actuators,

ignition lock components), Sun Roofs (stop cams),
Seating Mechanisms, Solenoids, Fuel Injectors
• Orthodontics – Brackets, Buccal Tubes
• Medical and Dental Instruments – Endoscopic
Surgical Instruments
• Firearm Components – Triggers, Sights, Safeties,
Seer Blocks
• Ordnance – Guidance Fins
• Hardware and Lock Parts – Lock Cylinders, Bolts, and
Sidebars
• Computers and Electronics – Disk Drive Components
• Electrical – Connectors, Switches

MIM Design Guidelines

 • Size – The economical part size is typically limited to
less than 100 grams due to the cost of the fine metal
powders used for MIM parts. Typically 1 to 20
micrometers in diameter (5 to 10 times smaller in
diameter than those used for conventional powder
metal parts), these fine metal powders are necessary to
drive the shrinkage needed to densify the parts during
sintering.
• Section Thickness – The maximum section thickness
is generally kept to less than 0.25 inch to remove the
thermoplastic binder effectively without causing
internal damage to the part. Uniformity of section
thickness throughout the part aids in preventing cracks,
sink marks, and distortion during sintering,
• Details - MIM can accommodate intricate design
features such as dovetails, slots, undercuts, threads,
and complex curved surfaces.
• Length-to-Diameter Ratio - MIM can produce
cylindrical parts with greater length-to-diameter ratios
compared to conventional powder metal processing.
• Fixturing – The availability of a surface somewhere on
the part that can support the part through the
debinding and sintering operations without special
fixturing simplifies the process and positively affects
the economics of the part.

MIM Materials Available from SSI-Sintered Specialties

• Stainless Steels - 304L, 316L, Duplex, 17-4PH, 430L,

440C
• Low Alloy Steels – Iron-Nickel (Fe-2Ni), 4600
• Soft Magnetic Alloys – Iron, Iron-Silicon (Fe-3Si)
Electrical Steel, Iron-Nickel (50Ni-50Fe)
• Low Thermal Expansion Alloys - F15, Alloy 36, Alloy
42
• Custom Blends

The Metal Injection Molding (MIM) Process

The Metal Injection Molding process is a multi-stage process
that converts fine metal powders into near full density, high
strength metal components. MIM competes with cast,
wrought, and machined metal components on the basis of
both manufacturing cost effectiveness and material
properties. The process consists of mixing fine metal
powders with thermoplastic binders to form a feedstock
which is injection molded into a closed mold. After ejection
from the mold, the thermoplastic “binders” are chemically or
thermally removed from the part so that the part can be
sintered to high density. During the sintering process, the
individual particles metallurgically bond together as material
diffusion occurs to remove most of the porosity left by the
removal of the binder. The sintering process shrinks the part,
providing a net shape that can be used as-is or further
worked to add additional features or improve tolerances.

Mixing

MIM feedstock begins with micron-sized metal particles. The

metal powders are hot mixed with thermoplastics chosen to
provide the necessary rheological properties for molding,
mechanical properties for handling, and chemical and
physical properties for ease of subsequent binder removal.
Good feedstock formulations balance numerous conflicting
cost and processing factors relating to both powder and
binder selection.

Molding

Standard plastic injection molding machines are used to

form MIM components. The feedstock is heated in the barrel
to soften the powder/binder feedstock to a toothpaste
consistency. This hot paste is injected into a closed mold
cavity and cooled prior to ejection. Robotic pick-off is
typically used to prevent handling damage. Runners and
gates are reground and reused, minimizing scrap loss at the
molding operation.

Debinding

Once the part is molded, the thermoplastic binders used to

help the powder flow into the die are no longer needed and
must be removed. First, a portion of the binder is removed to
open up a pore network within the part. The remaining
binder is subsequently removed through the open pore
network that has been created. This two-stage process
removes the binder without creating internal cracks or voids
within the part. There are several effective binder removal
methods in commercial practice, both thermal and chemical,
each with its own set of advantages and limitations.

Sintering

After the binder is removed, the parts are heated in a

protective atmosphere to a temperature high enough to
create metallurgical bonds between the powder particles
and cause densification. This process typically relies on solid
state diffusion and/or liquid phase formation to drive the
densification process. The parts typically shrink 15 to 20
percent from the original die size during sintering to achieve
final component density of 96 to 98 percent of full density.
Optimum sintering temperature depends on the material,
typically 2200°F to 2550°F (1200°C to 1400°C) for ferrous
materials.

Metal Injection Molding - A Unique Process

Raw Material

Fine metal powder sourced

from leading manufacturers, forms
the basic raw stock which is
thoroughly blended.

Compounding

Mixes the blended powder with

thermoplastic binders into a
feedstock.

Molding

The feedstock is injection molded to

form green parts.

Debinding

Removes the binder partially and

produces brown parts.
Sintering

Removes all the remaining plastic

content from the brown parts,
followed by inter particle
diffusion, resulting in the final
components.

Finished Parts

After sintering, the net

shape components are
ready without any
secondary operations.