Serving the Demanding Needs of the Auto parts / MIM Applications
Metal injection Molding (MIM), an emerging manufacturing technology across the world for the small, complex, precise & net shape metal parts.MIM Technology evolved from Plastic injection moulding & powder metallurgy is used for manufacturing complex-shaped precise metal parts.
MIM has been used primarily in the defence sectors & other important sectors to emerge have been in consumer goods, sports, telecommunication devices, medical & dental devices, hand & power tools. In the recent times, it has gained popularity in the global automotive sector as well.
The automotive industry demands parts with high performance and even higher reliability at a competitive cost and MIM (Metal injection moulding) is here to meet this challenge.
MIM has the following inherent capability because of which it is one of the best suitable manufacturing process for small, complex metal parts for automotive applications.
1. Product Design :
MIM can produce any shape that can be produced in thermoplastics by injection moulding with certain limitations to this general rule in both cases.
It offers various design advantages like manufacturability of features like hexagonal, square, splined, blind and flat bottom holes even at angles to each other, Knurled features , External / internal threads Logo / Part number / Raised letters / Impressions or Cavity ID are feasible. The various parts in the assembly can be integrated in to single piece design reducing manufacturing cost and the lead time.
2. Material variety :
Most of the metals and alloys available in MIM grade powder form can be processed by Metal Injection Moulding. But the metals and alloys that melt at temperature over 1000 Deg C (1832 Deg F) are more successfully processed by MIM.
For complex chemistry, there are three possible starting forms – Mixed elemental powders, fully compounded powders, or a hybrid of partially compounded and elemental powder. If the material is available or can be custom fabricated as a small powder then MIM is a viable production route. Of course, powder cost impacts the final component cost but the powder availability is the first consideration.
Selection of the proper material for a particular application often decides the success of a MIM project. The decision is made based on performance, cost, and input from a MIM part supplier or expert.
MIM materials have various advantages like homogeneous microstructure and Isotropic material properties. Parts can be fabricated out of difficult-to-melt alloys like tungsten heavy alloys with no interconnected porosity which is normally present in the PM parts.
3. Prototyping and low volume development
The low cost single cavity tools can be made for prototype and low volume development. We can produce few components which will be tested for functional tests before going for high volume production by which automotive manufacturers can validate the design by using the same production process as the one for high volume production.
4. High Volume production
The need of manufacturing technology for small, precise, complex-shaped parts in large volumes with short lead times and at competitive price has triggered the MIM technology. The multiple cavity tooling with automation can be made for high volume production.
5. Secondary machining process and Secondary finishing process
MIM parts are amenable for all the secondary operations similar to the ones on wrought or cast materials, like heat treatment, surface treatment, machining & joining and hipping operations, so they can be finished to any requirements as per the product design.
MIM automotive product solutions:
Safety Systems: Sensor housings, braking & ABS components, seat belt mechanisms.
Fuel Systems: injector nozzles, armatures, housings
Power-train: Turbocharger vanes and components, hydraulic spools, rocker arms
Electrical systems: Connectors, heat sinks
Interior systems: Seating mechanisms, cosmetic products
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