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Metal Injection Molding (MIM)

MIM Technology Process

Metal Injection Molding (MIM) is a metalworking process which allows shaping and manufacturing , geometrically complex parts in single operation and in high volume. The economic advantage in metal injection molded parts lies in complexity and volume for small-size parts.

ETP has in-house ability to design and manufacture tooling that can hold both the requirements of the finished part and the potential complications of the subsequent manufacturing process, which is the most important element in the success of the process .

The fine metal powder is mixed with binder s and additives (various thermoplastics, waxes, and other materials), resulting in a 'feedstock' capable of being granulated and then injection molded into single / multiple cavities forming a green component . The green components then pass through various processes like, debinding, sintering, and other secondary operations, resulting in a final desired shape.

Dimensional tolerances of +/-.003" per linear inch can be commonly attained, so as, far more closer restrictions on tolerance possibly can be attained with expert technical knowledge and experience in molding and sintering. MIM can produce parts where it is difficult, or even impossible, to efficiently manufacture an item through other means of fabrication.

Categories

MIM Technology Flow Chart

MIM Advantage

Parameter
MIM
Conventional PM
Machining
Investment Casting
Density
98%
88%
100%
98%
Tensile Strength
High
Low
High
High
Elongation
High
Low
High
High
Hardness
High
Low
High
High
Complexity
High
Low
High
Medium
Surface Finish
High
Medium
High
Medium
Production
High
High
Low
Medium
Range of Materials
High
High
High
Medium-High
Cost
High
Low
High
Medium

Material Properties

Material code Density
g/cm³
Hardness 
HRC/HRB
Tensile strength 
MPa
Elongation rate
 %
Iron base alloy Fe2Ni(normal state) 7.6 87HRB 530 16
Fe2Ni(Heat treatment) 7.6 50HRC 1630 3
Fe-8Ni(normal state) 7.58 92HRB 650 20
Fe-8Ni(Heat treatment) 7.58 55HRC 1750 5
Fe2NiCu0.5Mo(Heat treatment) 7.5 60HRC 1830 6
Stainless steel 316 7.7 68HRB 630 50
304 7.7 62HRB 600 70
17-4PH(sintered state) 7.65 25HRC 950 7
17-4PH(Heat treatment) 7.65 45HRC 1320 5
440C(Heat treatment) 7.6 60HRC 600 10
420(Heat treatment) 7.5 50HRC 950 7
Hard alloy YG8 14.5 87HRC bending strength 2400
YG3X 15 91.5HRC bending strength 2480
Tungsten alloy  95%W-Ni-Fe 18.1 30HRC 960 25
97%W-Ni-Fe 18.5 35HRC 980 18

Application Field

Automotive, Aerospace and Defense, Dental & Surgical Instruments , Communications and Cellular telephones, Semiconductors, Connector Hardware, Fiber Optic Connectors, Spray Systems, Hard Disk Drives, and Sporting Equipment.

 

 

Machining Capability

Item Machining Process Working Range /Table Loading 
最大加工范围及加工重量
Machining Accuracy ( mm )
项目 加工方式 加工精度(所有尺寸mm)
  加工范围
(XxYxZ)mm
加工重 Kg Hole Dia Tolerance
孔径公差 
  (孔Ø2~50时)
Circularity / Cylindricity
孔圆度 / 圆柱度      
     (孔Ø2~50 时)
Hole Distance
孔间距B  / 孔边距A公差 
      A or B ≤ 75时
Hole Perpendicularity 
孔轴线  
 [ ⊥ ]    孔深 T≤15 时
Hole  Parallelism 孔轴线 [ ∥ ]   孔深 T≤15 时    Surface roughness 表面粗糙度    Ra(μm)   
                 
1 Milling Machining
普通铣削加工 
914*406*406 700  ≥ ± 0.01 0.01~0.03  ≥ ± 0.02 0.01~0.03 0.01~0.03 1.6~3.2  
2 High Speed Milliing Machining
高速CNC铣削加工 
800 * 500 400  ≥ ± 0.005 0.008~0.02  ≥ ± 0.01 0.008~0.02 0.008~0.02 0.8~1.6  
3 Wire Cut W/C 
放电加工   
350 * 250 200  ≥ ± 0.0025 0.0025~0.005  ≥ ± 0.0025 0.0025~0.005 0.0025~0.005 0.2~0.4  
                 
    Hole Dia Tolerance
孔径公差 
     (Ø  1.0 ~ 50; L ≤ 50 时)
Plane  Tolerance
平面度 
     (≤75x75; T ≥ 3.0 时)
Perpendicularity 
垂直度
 [ ⊥ ]    ≤75x75时
Parallelism 
平行度
  [ ∥ ]   ≤75x75,T≥3.0时
Circularity / Cylindricity
孔圆度 / 圆柱度 
  (孔Ø2~50 时, L ≤ 50 时)
Concentricity
同轴度     
  (孔Ø2~50 时, L ≤ 50 时)
Surface roughness
表面粗糙度  
   Ra(μm)   
  Turning
普通车床   
Max:Dia.     Ø 300 750  ≥ ± 0.01  --  --  -- 0.01~0.02 0.01~0.02 0.8~1.6
  Min:Dia.      Ø 0.50 10
  Precision Surface Grinding Machine
平面磨床 
370x160 75kg  -- 0.005~0.01 0.005~0.01 0.005~0.01  --  -- 0.2~0.4
  Single Lappping Machine
单面研磨机  
Max Ø130  Thickness: 1~50  -- 0.005~0.01  -- 0.005~0.01  --  -- 0.05~0.2
  Max Ø130  厚度 1~50

Inspection Equipment

Department: Inspection Instrument ( Production Equipment Total List ) NO:006
S.No.
Equipment Name
Machine Number
Quantity
Remarks
1.
Height Gauge
ETM001
1
2.
Micro scope
ETM002
1
With Optics Ruler
3.
Gauge Block
ETM003
1
Including optics ruler,and Disk
4.
Digital Calliper
ETM004
1
5.
Profile Projector
ETM005
1
optics ruler, detailed listing floppy disk
6.
Pin Gauge
ETM006
1
7.
Micrometer
ETM007 - ETM008
2
Optics ruler
8.
Micro-Dial-Indicaor
ETM009
1
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