Three Most Costs of Metal Injection Molding

As we conduct a MIM part manufacturing project, the small price change in one single process might lead to huge difference due to the massive quantity.

Metal Injection Molding processes include granulation, compounding, injection, de-binding, sintering, and finishing. If we could know which several processes cost much, we could optimize these processes purposefully so we can improve our efficiency and save a lot of costs.

Below analysis all based on practical cases by ZCMIM, there are slight differences between different manufacturers. When you got different detailed classifications of inquiry from a factory, you need to delve into those prices and ratio, then decide to cooperate with which factory.

The third most cost: Feedstock

Compared to traditional powder metallurgy using powders, MIM has higher requirements about the quality of powders, in addition, the supply of binder, feedstocks is an important outlay.

Optimization:

Improving the proportion of qualified products, and maximum using of feeding.

The second most cost: Sintering

It’s about the long duration of this process(normally considered 24 hours or more).

Optimization:

You can’t roughly shorten time to end up with sintering, I’m assuming that will work by improving technology in nearly future.

The most cost: Finishing

It depends, some MIM parts cost very little on finishing, but most of them spend more on finishing than other processes, the finishing includes plating, coating, manually testing, shaping, blasting, etc. And nowadays these processes are not suitable for automaticity.

Optimization:

Strengthen training and develop an experienced and skilled workforce to reduce the number of employees and labor payment.

Beyond that, tooling is also a huge cost when beginning, especially you are not sure if it could be better, you should discuss with engineers to get the best solution for your project. And roughly 2000 dollars seems not cheap when the quantity is small.

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The Primary Choice of “Green Auto” Manufacturing-Metal Injection Molding

Metal injection molding products(mim parts) used in automobiles are very high-tech products that can reduce the weight of automobiles and reduce the manufacturing costs. They also have the function of optimizing the production technology of automobile industry products and enhancing the competitiveness of the automobile industry. Currently, the metal injection molding parts are used in automobiles has more than 400 kinds.
As a typical net-final manufacturing technology, metal injection molding has advantages in many aspects such as energy saving, material saving, environmental protection, economy and high efficiency, and has been gradually recognized by various industries and widely used; especially, the application of automotive metal injection molding products With the rapid development of the metal injection molding industry has promoted the rapid development of the lane.

Metal injection molding parts can reduce costs and vehicle weight

metal injection molding parts used in automobile manufacturing are mainly sintered metal oil-bearing and metal injection molding structural parts, the former is mainly produced by 90Cu-10Sn bronze, the latter is basically made of iron powder as the basic raw material. Here are some examples of metal injection molding technology applications:
A metal injection molding 64-tooth power take-off drive gear saves about 40% less costly parts machined from steel and does not require subsequent machining of gears; a metal injection molding automotive manual transmission synchronizer ring, as compared to conventional production Of the synchronizer ring, can reduce the cost of 38%; a metal injection molding compound planetary gear carrier, the ultimate strength of castings than the cast iron 40% higher, while reducing the cost of more than 35% ...

Many award-winning mim parts show that metal injection molding parts cannot only replace die-casting parts, forgings, machined parts, it can save labor, save material, save energy, reduce production costs, but also reduce the weight of parts, which is conducive to lightweight vehicles. More importantly, the development of metal injection molding combination parts, marking that some parts can only be made using metal injection molding technology, has important technical and economic significance.

Metal Injection Molding is a “green manufacturing” technology

At present, metal injection molding has been recognized by the industry as a green, sustainable manufacturing technology.
In terms of continuous functionality, the ultimate metallization power and material utilization of metallurgical powder metallurgy minimize total energy consumption. Compared with the traditional process (hot working + cold working), casting or forging + cutting, metal injection molding process to manufacture the same part requires only a few steps, which can be completed more processes, more complex processes. The ultimate strength of metal injection molding is its main strength in terms of material sustainability.
For example, forming a toothed part can result in up to 40% of the material turned into chips in conventional cutting processes, whereas 85% of the total powder metallurgy is produced from recycled material. In the production of metal injection molding parts, waste loss of each process is generally 3% or less, the material utilization rate of up to 95%.

In terms of energy sustainability, the conventional traditional manufacturing process requires several heating and reheating processes to finalize the shape. When atomizing the steel powder or iron powder, only the scrap material needs to be melted once, and all other heat Processing operations are carried out below the melting temperature of the temperature, so that not only energy saving but also can be made into the final shape and the formation of the required material properties, mechanical properties. A comparison of material utilization rates for metal forming found that the energy required to make metal injection molding parts was 44% of forged-machined parts.
In terms of environmental sustainability, due to the ultimate shaping ability of metal injection molding, finished parts are usually produced after sintering, ready for packaging and delivery. In most cases, the cutting oil used to process metal injection molding products is negligible, and the amount of toxic pollutants released by sources such as cooling water is small. Compared with other manufacturing processes, the metal injection molding parts industry is almost harmless to the environment.
Metal injection molding parts is already an indispensable basic type of automobile industry, many world-renowned metal injection molding enterprises have also established wholly-owned enterprises in China, personally believe that in the near future, China will gradually become one of the largest distribution centers of auto mim parts.

Metal Injection Molding To Promote The Industrialization Of Powder Metallurgy Made A Breakthrough

In the process of understanding the powder metallurgy technology, we came into contact with metal injection molding process, did not expect it completely different from the ordinary forming technology, in the mass manufacture of complex geometry, high performance, high precision parts must have no difficulty, So as to promote the industrialization of powder metallurgy business to make a breakthrough.

Powder metallurgy companies in the metal powder injection molding time, in addition to the need to prepare the appropriate processing of the corresponding powder, but also need to add more powder to the binder. Therefore, either powder or binder should meet the requirements, otherwise it will affect the forming of powder metallurgy products.

The powder should be used ≤ 10um ultrafine spherical powder, and from the mixture to degreasing, sintering, the process is more complex, demanding processes, in particular, require longer degreasing and sintering time, which is also caused by the manufacturing cost of powder metallurgy High main reason. The adhesive wolf must be adequate, otherwise, it is difficult to achieve the corresponding performance.

This powder metallurgy company developed a simplified method is flow pressure forming technology, which is the temperature and pressure of metal powder, based on the combination of the advantages of metal powder injection molding process; and then by adding the right amount of coarse powder and fine Powder, and increase the amount of thermoplastic lubricant, thereby greatly improving the mixed powder flowability, filling and formability.

Since the mixed powder becomes a viscous fluid with good fluidity during pressing, it not only has the advantages of a liquid but also has a high viscosity and reduces the friction force, so that the pressing pressure is evenly distributed in the powder, Very good delivery. Because of this, the powder can flow to every corner without cracks during the pressing process, so that the density is also greatly improved.

At present, the powder metallurgy enterprise has already popularized this technology and used for precision forming of the workpieces with very complicated shapes on the conventional tablet press. This not only overcomes the shortcomings of the traditional cold pressing in forming complicated geometric shapes, but also avoids the high injection molding technology cost.

Top 6 Metal Injection Molding Defects and Solutions about Debinding

In the injection molding debinding process, there is great chance to meet some common issues, below we list top 6 issues we might meet, and solutions to help you better on metal parts manufacturing.

Defect 1: Fluff

Causes and solutions:

A. POM split too fast, usually only need to reduce the temperature, reduce the amount of acid and increase the debinding time;

B. Feeding paraffin too many ingredients, with this problem need to replace the raw materials;

C. Mold, need to modify the mold structure;

D. Injection temperature is too high, need to reduce the temperature.

Defect 2: Cracked or broken.

To check for the following four reasons whether there is a defect

A. The placement of the workpiece, if any questions please put correctly;

B. Same as the POM split too fast, the solution is the same as above;

C. Shock, if found to have vibration to find the source of vibration and solve;

D. Workpiece density and weight are not up to standard, need to change the injection process.

Defect 3: Uneven debinding in the furnace

Causes and solutions:

A. The way the product is placed, need to adjust

B. B. Check the furnace temperature difference, need to test the temperature

C. There are dead ends in the furnace, need to improve the circulating air speed

Defect 4: Color change

Causes and solutions:

A. The temperature is too high to reduce the temperature

B. Nitrogen flow is insufficient, need to increase the flow

C. Feed the wax content is high, need to adjust the feed

Defect 5: Incomplete debinding

Causes and solutions:

A. Process setting, need to change the process

B. Debinding time is short, need to lengthen the debinding time

C. Nitric acid concentration is low, need to check and replacement

Defect 6: Debinding layered

Causes and solutions:

A. Debinding temperature is too high, need to reduce the debinding temperature

B. Debinding rate is not enough, need to increase the amount of acid entering

As an advanced China MIM factory, we keep providing precision MIM parts for customers from all over the world.

MIM technology has become the most active cutting-edge technology in the new manufacturing industry

Metal Injection Molding (MIM) is a new near net- forming powder metallurgy technology which is formed by bringing powder metallurgy in modern injection molding technology. Its basic MIM process is: mixing metal powder and binder evenly at first. Then granulating the mixture, and injecting into mould cavity in plastic state to shape product. Using chemical or thermal decomposition method to remove blanks, final products will be obtained finally after sintering.

Compared with traditional process, metal injection molding (MIM) have several advantages like high precision, uniform organization, superior performance, low production costs. Its products are widely used in electronic information engineering, biomedical equipment, office equipment, automotive, machinery, hardware, sports equipment, weapons and aerospace industries. Therefore, the international generally believe the development of metal injection molding will lead to revolutions on part forming and processing, known as "21st century molding technology."

The Parmatech company from California invented this technology in 1973, in early 80s, many European countries and Japan companies also put a lot of effort on technology research, and promoting. Especially in the mid-eighties, industrialized technology development is more rapid, growing at an alarming rate every year. So far, more than 100 companies from the United States, Western Europe, Japan etc… more than a dozen countries and regions, engaged in product development and sales. Japan is very active in the competition, and performs outstanding. Many large companies are also involved in the promotion of MIM, including Pacific Metal, Mitsubishi Steel, Kawasaki Iron and Steel, Kobe Steel, Sumitomo Mining, Seiko, Epson, Datong Steel, and so on. At present, Japan has more than 40 companies specialized in MIM industry. The sales value of MIM product has already surpassed Europe and caught up with the United States. MIM technology has become the most active cutting-edge technology in the new businesses. It’s the world's pioneer metallurgical technology, representing the main development direction of powder metallurgy Technology.

Metal powder injection molding technology combines the plastic molding process, polymer chemistry, powder metallurgy technology, metal materials and other multidisciplinary. It can be said a new change for manufacturing industry. The process not only has the advantages of conventional powder metallurgy technology --no need cutting or cutting less, high economic efficiency, but also overcomes the shortcomings of traditional powder metallurgy such as material uneven, low mechanical properties.
www.zcmim.com/article/MIM-technology-cutting-edge.html

How to choose Metal Injection Molding or Die Casting?

Actually there are so many similarities between Metal Injection Molding(MIM) and Die Casting, Both of these two metal parts producing methods take use of mould, and their producing process are sort of similar, melt metal injected into mold and forming, manufacturers always like take these two producing methods. Therefore, how to define if a metal components project is suitable for Metal Injection or Die Casting?

1.Raw Materials

Commonly used materials for

Die Casting: Aluminum Alloy, Magnesium Alloy, Zinc Alloy, and Copper Alloy in designated circumstance.

Metal Injection Molding: Varieties of Stainless Steels, Iron based.

If we dig deeper, we would find that the biggest diffence between Metal Injection Molding and Die Casting raw materials is melting point, as the melting point is higher of Metal Injection Molding, in Metal Injection Molding, the shape of raw materials is powder, and we would add binders into MIM process, and then sintering process, which is like “oven” process.

As Die Casting usually take formed materials, so we can see that Metal Injection Molding have higher raw materials requirements but more complicated producing process.

2.Size and Weight

The range of Die Casting size is much wider than Metal Injection Molding. It also means Metal Injection Molding have limitation in size nowadays, usually can produce metal parts under 200g.

For the product’s weight of these two manufacturing methods, due to the “binders” wouldn’t remove completely in MIM process, whereby the MIM components would be lighter. In the “lose weight” stream of many industies today, it’s an very important way to achive.

3.Quantity and Costing

Costing is always an important fector when choosing manufacuring process. While the quantity is always an important factor need to be consider. And both of Metal Injection Molding and Die Casting must make mold.

But in generally, when quantity is exceed one specific number, Metal Injection Molding would cheaper than Die Casting.

In any way, the best important reason to choose Metal Injection or Die Casting is raw materials, and specific individual requirements of each metal part project. Last but not the least, take consideration about the quantity for budget control.

ZCMIM, the advanced Metal Injection Molding Manufacturer in China, always offer the best choice for customers not just MIM.

degreasing equipment

Degreasing process is a process with the characteristic of metal injection molding technology, according to the different way of working equipment, degreasing equipment can be divided into the batch of material type degreasing furnace, catalytic degreasing furnace, for metal injection molding using in practical production more paraffin base binder system, thermal degreasing is the most commonly used, and most important degreasing method, catalytic method was advanced degreasing degreasing is relatively new, but its have special request for feeding, the following focuses on industrial production the commonly used thermal degreasing furnace, solvent degreasing furnace and catalytic degreasing furnace.

Original article link：http://www.zcmim.com/article/degreasing-equipment_1.html

sintering metal injection molding

metal injection molding after sintering, the future to meet the requirements of customers, sometimes need to surface finishing process, the sintering products such as surface finishing and deburring, round, and brightening.Application of planetary processing principle, the pieces of a certain number of artifacts, grinding, water and abrasive, added to the roller, the volume of the cylinder volume 40% - 40%, application of ceramics, alumina, aluminum alloy, aluminum alloy ceramic grinding block on the surface of the irregular parts processing edges and corners, deburring, chamfering, flash, oxide skin, rough cast batch processing, can improve the finish 2 - level 3, rough after grinding can improve the parts precision grade 1 or 2, chip removal process before leaving the establishment and one-time whole sintering after the flash light, to improve the surface contact fatigue strength of parts.

Original article link：http://www.zcmim.com/article/metal-injection-molding-sm_1.html

metal injection molding and injection process

metal injection molding production success depends on the accurate uniform control of the products, to ensure the dimensional change from one product to another product and can be repeated, caused by injection to poor control of the process of change in sintering stage is difficult to correct, in the stage of sintering, the situation is usually enlarge the difference between the part and part, the loss of dimensional accuracy is often erroneously think is the problem of sintering, as long as appropriate to control the sintering temperature, sintering can get the final size of the uniform, so that when the size control problems, before the big change of sintering process is a good idea to look at the injection process.

Original article link：http://www.zcmim.com/article/meta-linjection-molding-aip_1.html

metal injection molding of stainless steel

Now the most widely used metal injection molding of stainless steel 316 l stainless steel and 17 - PH stainless steel, 316 l stainless steel is a kind of good structural material, has good comprehensive mechanical properties, with the traditional moulding and sintering of powder metallurgy technology can produce stainless steel, but its density is low, the existence of the pore reduced mechanics, corrosion resistant, apparent, such as performance, and is limited to a simpler shape parts, thus restricted its development, industrial scale production of MIM stainless steel parts size accuracy + / - 0.3% ~ 0.3%, generally do not need to subsequent machining, density can reach above 95% theoretical density.Mechanics, corrosion resistant performance and so on, the apparent and molten stainless steel forging.

Original article link：http://www.zcmim.com/article/metal-injection-molding-oss_1.html

the sintering of metal injection molding

Metal injection molding of sintering and general powder metallurgy sintering process is similar, but the metal injection molding using a large amount of binder, the forming of billet density is low, the binder is removal before sintering, so injection molding billet sintering is a bit similar to apparent sintering, the sintering process can produce larger shrinkage, although the contract is our main purpose of the sintering, but at the same time the size change has led to distortion, to maintain high precision needs to be controllable and uniform sintering shrinkage caused by the evolution of the microstructure is a main factor of product performance.

Original article link：http://www.zcmim.com/article/metal-injection-molding-tsom_1.html

Metal Injection Molding - Viscosity Measuring Instrument

Choice of viscosity measuring instrument depends on viscosity size. There are mainly two types of viscometer: 1. Dispersed system suitable for low viscosity.  2. Capillary viscometer suitable for larger viscosity.  Regarding feedstock used in metal injection molding, because the viscosity is higher, capillary viscometer is better.

Original article link：http://www.zcmim.com/article/metal-injection-molding-wmid_1.html

How Many Binders?

Big binder has been applied to metal injection molding industry, different binder reflect difference between powder properties and de-binding process. The binder in injection molding process can generally be divided into five types, most of them are compounds, specific classified as: thermoplastic polymer, thermosetting polymer, inorganic polymer, gel system, inorganic substance

Original article link：http://www.zcmim.com/article/binder-metal-injection-molding_1.html

metal injection molding process of phase

Metal injection molding process can be divided into several stages: raw materials selection, mix in granulating and granulating, molding, debinding and sintering, etc., each stage has its special role.Powder and binder mixing process is one of the most important step, a mixture of powder and the binder is called feeding.Injection molding process for feed has good uniformity, good rheological property and good degrease performance.Only take care of the three ways of metal injection molding feeding is a successful feeding system.

Original article link：

http://www.zcmim.com/article/metal-injection-molding-process-opmp_1.html

metal injection molding the material system direction

Metal injection molding technology is ideal, able to shape, the shape, eventually need to be close to the economy only little or no need to follow-up after sintering processing of near net shape technology, this in industrialized production and application of the ceramic becomes more and more important, in the production of precision ceramics is mainly used to carbide, metal ceramics, pottery, inorganic nonmetal oxide ceramics, intermetallic compounds, etc.

Original article link：http://www.zcmim.com/article/metal-injection-molding-mimtmsd_1.html

Practice of Metal Injection Molding Technology

As applying fine powder and a large amount of binder, the process and mechanism of metal injection molding technology changed great compared with traditional powder metallurgy suppressing/sintering process. There are many new foundation theory and practical problems like plasticizing rheological behavior of powder/binder, process forecast and control for feeding filling cavity steadily, physical chemistry mechanism and dynamics for removing binder from green part, densification loose powder and so on.

Original article link：

http://www.zcmim.com/article/metal-injection-molding-technology-pomit_1.html

Powder Forging

Powder forging is also called beforehand hot parison. It is the composite technology in preheating section of metal injection molding. Parts made of this method, theoretical density can be up to 99.4%. It is mainly used for iron based parts, the main material is carbon steel and low alloy steel, also high temperature alloy. The strength of brocade based high temperature alloy part made in this way - temperature performance surpassed that made by traditional method.

Original article link：http://www.zcmim.com/article/powder-forging-sdgvc_1.html

metal injection molding with foreign development gap in China

Metal injection molding industry in China have been nearly 10 years of rapid development, but with foreign industry still exists the gap between the following aspects: (1) enterprises, small scale, economic benefits is a long distance with foreign enterprises.(2) the product cross, enterprise interacting each other, the competition is fierce.(3) the majority of enterprises lack of technical support, research and development capabilities, products is low, it is difficult to compete with foreign.(4) lack of again and obsession.(5) process equipment and supporting facilities behind.(6) products export, trade channels.

Original article link：http://www.zcmim.com/article/metal-injection-molding-mimwfosd_1.html

Metal Injection Shock Absorber Parts

Metal injection molding(http://www.zcmim.com/) is used in industrials and electronics. It is also being applied to automatic absorber parts, motorcycle shock absorber, piston rod and piston guide valve such kind important components. Considering the stable damping force of shock absorber, powder metallurgy part has high precision sheet surface, can reduce friction and guarantee the stability of operation, improving comfort as well.

Original article link：http://www.zcmim.com/article/metal-injection-molding-msap_1.html

Mobile Phone Processing Technology In 2017

Since the appearance of Xiaomi 5 ceramic glass shell in 2016, it brands new image of mobile phone. there is also news that iphone8 will use stainless steel and composite materials to explain a new generation of mobile phone shell. From process, the industry mostly used many milling to machine blank into shape, namely the so-called integrated molding technology. Through CNC, injection molding, polishing,grinding and anodic oxidation treatment can finish manufacture. In addition, stamping and die casting process are also used among them. Although metal injection molding (injection molding and metal injection molding) shorten production cycle, saving materials and reducing cost, but some bubbles happened in injection and uneven cooling question when melt combined with mould needs to be improved. Whether mobile phone processing technology stand out from the competitionin 2017, we look forward to it!

Original article link：http://www.zcmim.com/article/metal-injection-molding-jppti_1.html