AUTOMOTIVE 

Fuel Pump
  • Material: MIM 4605  (Medium Carbon Steel)
  • Weight: 9 gm
  • Segment: Automotive
  • Density: 7.89 g/cc
  • Hardness: 100 to 250 HB
  • UTS: 320 MPa
  • 6 separate machining operations for every part
  • Problem faced in repeatability and burr formation
  • High machining cost
  • Entire profile is manufactured through MIM
  • Large batch production with auto rewinding mechanism for thread in tool
Shock Observer
  • Material: MIM 4605  (Medium Carbon Steel)
  • Weight: 12gm
  • Segment: Automotive
  • Density: 7.89 g/cc
  • Hardness: 35 to 40 HRC
  • UTS: 1200 MPa
  • Complicated profile with 18 holes of dia. 3.75 mm and 6 thin ribs of 1.5 mm
  • Challenging to fill sections completely in the molding stage
  • Component manufactured close to net shape, with surface grinding to achieve flatness (10µm) and facing operation to achieve height tolerance
Valves
  • Material: SS 17-4PH and MIM 4605
  • Weight: 26gm to 32gn
  • Segment: Automotive
  • Density:
  • Hardness:
  • UTS:
  • Multiple manufacturing operations
  • Joining operations for assembly
  • Integrated parts without joining operations
  • Compact parts with reduction in weight
GEAR ASSEMBLY
  • Material: MIM4605
  • Weight: 14gm
  • Segment: Automotive
  • Density:
  • Hardness:
  • UTS:
  • Gear and pin machined separately and welded to make a single component.
  • Welding area prone to fracture due to Torque
  • Component molded as a single assembly eliminating the joining operation and improving strength

CONSUMER

Sport Equipment
  • Material: MIM 17-4PH
  • Weight: 15gm
  • Segment: Consumer
  • Density: 7.75 g/cc
  • Hardness: 36 to 42 HRC
  • UTS: 1220 MPa
  • Complex profile with features like curved profile , undercut and inclined geometry is difficult for conventional machining
  • Near-net shape achieved in the tool itself with all the complex profile features, eliminating all the secondary machining operations
Sanitary metal Parts
  • Material: MIM 316L
  • Weight: 20-40gm
  • Segment: Consumer
  • Density: 7.6 g/cc
  • Hardness: 100 HRB Max.
  • UTS: 480 MPa
  • High lead time, low repeatability & difficult to produce component in high volumes
  • Fragile features and thin walls difficult to develop through conventional process
  • Burr folding at sharp corners
  • The entire component was produced through MIM with no additional machining operation
  • Three complex parts are fabricated close to the net shape and special ceramic setters are employed for enhanced shape retention during sintering
Gas Sensor
  • Material: MIM 316
  • Weight: 3-5 gm
  • Segment: Consumer
  • Density: 7.65 g/cc
  • Hardness:
  • UTS:
  • Earlier manufacturing process – Powder Metallurgy :
    • Mirror finishing in PM is difficult to achieve due to coarse size of metal powder.
    • Cost and lead time of Buffing process was more in Powder Metallurgy.
  • Due to fine size of metal powder mirror finishing is easily achieved in MIM process.
  • Cost and lead time of buffing in MIM is less as compared to PM.

MEDICAL

Surgical Stapler
  • Material :- MIM 17-4PH
  • Weight :- 1.1gm
  • Segment :- Medical
  • Density:
  • Difficult to consistently maintain low corner wall thickness
  • High strength requirement
  • Customized staging ceramic fixture used to avoid distortion
  • High strength achieved through modified material
  • Material: MIM 17-4PH
  • Weight: 0.9gm
  • Segment: Medical
  • Density: 7.8 g/cc
  • Hardness: 30 HR15N
  • UTS: 300 MPa
  • 0.3mm wall thickness for the length of 11.4mm is challenging through conventional process
  • High volume component
  • Near net shape and complex features achieved through MIM
  • High volume easily achievable