Relative Cost vs Complexity

The goal with MIM is to eliminate as many post secondary operations as possible.

MIM is capable of  making parts with:

  • The flexibility and detail of plastic injection molding
  • Similar material properties to wrought machined products
  • Complex features that are difficult to machine
  • Precision tolerances (±0.5% inch per inch)
  • Cost effective customer pricing
  • Uniform wall thicknesses between cross sections are ideal (wall thicknesses can change, as long as gradual transitions are applied)
  • Coring (material equals cost, so reduce material by coring thick sections that are non-functional with gradual transitions;  coring perpendicular to parting line will not increase tool cost drastically; coring parallel to parting line is possible, but will increase tool cost)
  • Sintering supports (large flat sections are preferred for sinter staging; if there is not a large flat section, APG does offer custom setters for sintering)
  • Draft (plastic injection molding principles apply; 2° of draft is ideal, but sections of 0° draft are achievable)
  • Radii & Fillets (radii & fillets are achieved in the tool; radii greater than 0.008” are preferred on outside corners; fillets are preferred on internal corners to aid material flow)
  • Holes & Slots (both can easily be added to the mold; holes or slots perpendicular to parting line will not increase tool cost drastically; holes or slots parallel to parting line are possible, but will increase tool cost and process time; hex, square, and D shaped holes are all welcome)
  • Undercuts (external and internal undercuts are both possible; external are easily produced; internal are more of a challenge; if undercut is open on one side it can be formed with a slide; if not, it would need formed with a collapsible core which is not preferable in the MIM process)
  • Threads (internal and external are both moldable; external threads require parting line flats (0.005” –0.015” will typically suffice); internal threads require an unscrewing core and significant mold cost; machining internal threads is the preferred process)
  • Texturing, Lettering, & Logos (all are possible either perpendicular or parallel to parting line)

Material Options

  • Stainless Steel (303, 304, 310, 316, 430, 410, 416, 420, 440C, 17-4PH, 465)
  • Low Carbon Steel (1010, 4140, 4605, 4630, 8620)
  • Specialty Steel (inconel, cobalt chrome, titanium, tool steels)

MIM Process

Casting

Relative Cost

MIM combines two existing technologies:

  • Plastic Injection Molding
  • Powder Metallurgy

Machining

MIM

P.O. Box 1819

West Chester, OH  45071

Monday - Friday

8:00 am - 5:00 pm

Complexity

Powdered Metal

"We represent the manufacturer"

  1. Feedstock Compounding (pelletized from raw metal powders and polymer binders dry mixed to form a homogenous blend)
  2. Molding (standard injection molding machine with upgrades)
  3. Debinding (solvent; thermal, catalytic)
  4. Sintering (large batch, small batch, continuous pusher furnaces)
  5. Post Sintering (machining; heat treating; passivating; plating; hot isostatic pressing; deburring; grinding)

MIM Guidelines

D&D Engineered Components

Phone

419.708.5313

Metal Injection Molding Services