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.

Original Resource

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

mixing equipment

Is the purpose of the mixed layer on the surface of powder coated adhesive, destroy the reunion, the binder and the powder particles uniformly distributed in the whole feeding, mixing is the first step of the MIM process and important working procedure, because the defects in feeding cannot eliminate by the adjustment of the steps behind, so the quality of the feed is key.For mixing the powder and binder content in all parts of the feeding uniform, at the same time can reduce the time needed for mixing feeding, maximize the powder in the binder content, avoid the binder and the powder of two phase separation, the phenomenon such as powder segregation in the binder, need according to the nature of the material selection of different mixing equipment and make reasonable mixing process.

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

Why MIM Suitable for Small Size Product?

MIM process joins a large number binder. Its sintering after removing binders is similar to traditional powder metallurgy sintering. Taking fine powder as raw material can meet the requirement of densification, which results in cost increase greatly. If large size products still adopt fine powder, it will be not competitive. At the same time, due to product size increasing, degreasing time increased accordingly, and the defect occurrence probability increase greatly. In addition, product size increased, injection molding time increased so as for higher requirements for rheological properties of binder in order to carry powder quickly to different parts of the cavity. All above are factors restricting MIM products to larger size. Hence MIM technology has been confined to smaller size, high accuracy product.

Original article link：http://www.zcmim.com/article/mim-process-wmsfss_1.html

MIM Process- Preferred ZCMIM

Rely on low cost, simple, fast forming of MIM process and tight texture, uniform organization, superior mechanical properties, high precision, small tolerance of MIM products, coupled with modern powder metallurgy composite materials such as the improvement of high temperature alloy quality, more high performance, high quality aircraft and auto parts will appear in the future production. In the era of big manufacture approaching, MIM technology is sure to distinguish! Preferred ZCMIM for Metal powder injection molding, welcome to inquire.

Original article link：http://www.zcmim.com/article/mim-process-mppz_1.html

how to promote the MIM technology rapid development of China?

How to promote the rapid development of MIM process of China?Come and see what the MIM manufacturers zcmim say.

1, to establish the new mechanism of integration of trade and industry production and development

2, strengthen the research and scientific guidance to the development of the industry planning

3, the high technology industry development policy

4, actively seeking international technology cooperation

Original article link：http://www.zcmim.com/article/mim-process-htptm_1.html

The MIM Process of Three Steps

MIM process(http://www.zcmim.com/helps/mimprocess.html) requires three steps:

(1) In condition of heating, pressure, injection the mixture of powdered metal and thermoplastics (or other binder) into mold cavity (similar to thermoplastic injection molding).

(2) Removing binder by heating or melting, only the metal powder left.

(3) Sintering the metal powder. Sintering temperature should be lower than the melting point of metal, but enough to make metal powder combined into solid metal (actual solid metal density is more than 96%).

Original article link：http://www.zcmim.com/article/mim-tmpot_1.html

What Materials can be Used for MIM process

Almost all of metal alloys are available in MIM process(http://www.zcmim.com/helps/mimprocess.html), typical alloys including high strength steel, stainless steel and nickel alloy and super alloy. Other materials including refractory alloys, titanium and copper alloys, low melting point alloy including brass, bronze, zinc, aluminium, but not economic in MIM process. Taking Indo - MIM material selection for reference.

Original article link：http://www.zcmim.com/article/mim-process-wmcbi_1.html

the MIM process cooling time

The MIM process(http://www.zcmim.com/helps/mimprocess.html) cooling time (4 to 7) when the melt into the cavity, touching the metal surface, melt cooling step is already started.Because of polyformaldehyde, nylon, and polyethylene semicrystalline materials such as carbon solidification temperature is very high, so little time to cooling.If the general module, after completion of the melt, the module should have enough cooling time.If you find a problem when ejection module, can extend the cooling time, slowly until problem solving.

Original article link：http://www.zcmim.com/article/mim-process-tmpct_1.html

Why Choose Metal Injection Molding Company ZCMIM?

Metalinjection molding company –ZCMIM, focus on MIM process. It can customize any small complicated shape, three-dimensional metal parts. we own a professional MIM engineering team.

We got ISO certification and has more than 8 years production experience, more than 5 years exporting experience. Daily output is up to 300k. Factory area is more than 8000 square meters, Distinguished surface treatment is outstanding among domestic MIM factories. Surely ZCMIM will give you more and more surprises!

Original article link：http://www.zcmim.com/article/metalinjectionmoldingwcmimcz_1.html

German customer Visit ZCMIM factory

A German customer visit our factory yesterday. Their company are mainly profession in auto and lockset industries. They have close good cooperation with most German car companies. Nearly 46% projects will be made by MIM process.

This customer also have MIM supplier in Turkey, Germany, Japan, South Korea. And right now they want to seek one more Chinese MIM supplier for long term cooperation. After inspecting our workshop and engineering, he feedback very confident with our quality control. He commented our factory is a well-organized plant. He also have very good suggestions for us about mould protect, marketing advertisement and World Powder Metallurgy Exhibition preparation . Within the following months, our first project will be launched.

Recently months, more and more customers scheduled visiting ZCMIM. We hope that ZCMIM can achieve more and more recognition. From 9^th~13^th October, we will take part in World PM2016 Congress and Exhibition. It is held by European Powder Metallurgy Association in Hamburg, Germany. Both our chief engineer and general manager will be there. Welcome to give us RFQ and make face to face discussion with us in exhibition.

Original article link：http://www.zcmim.com/article/mimtechnologygcvz_1.html

What UAV&Drone Parts can be Manufactured by MIM Process

Drone shaft, remote control buttons and spindle are all can be made by metalinjection molding MIM. After sintering, the products will make several tests like tensile strength test, impact toughness test, bending test. Compared with traditional PM process, The MIM parts have great advantages in mechanical properties, surface quality, shape complexity, material utilization, as well as production efficiency.

Australian customers to visit the ZCMIM factory

The product engineer Charles from ORBITKEY came to vist our factory yesterday. We discussed all the details one by one for project at hand and also explain MIM process to Charles, This is the first time for Charles to know MIM, therefore the visit is full of curiosity. He was very satisfied with our engineering, QC and factory atomsphere.

Regarding current discussed project, everything is done except should make a little change for product structure to achieve better surface. Charles said he would be double check for it once back.

Customer web site: www.orbitkey.com

ZCMIM powder metallurgy metal injection molding can be applied to what industry?

specializing in the production of small and complex metal parts, mobile phone metal parts, medical machinery parts, industrial metal parts, such as metal parts, set custom, processing, sales of one-stop service. ZCMIM powder metallurgy metal injection molding can be applied to what industry? With small make up to see it!

1, mobile phone equipment

In fact, there are several parts of the phone is the use of metal injection molding method. For example: the manufacturing tungsten vibrator balance weight, use made of high strength steel hinges, metal injection forming method in mobile phone is one of the most important application is to create a slide, barrel and a hinge.

In addition, due to the need for lighter, thinner and more beautiful mobile phone market and need to use the best technology, reduce their size, a mobile phone company is seeking for metal injection forming method for manufacturing the assembly parts of the mobile phone.

2, medical machinery parts

Metal powder injection molding technology in the processing of medical machinery parts also played a relatively large role. For example, orthopedic rack teeth, scissors, tweezers etc..

3, ordinary household appliances

In addition to the above two industries, the technology can also be used in the manufacture of ordinary household appliances. For example, watchcase, watch chain, electric toothbrush, scissors, fan, golf head, jewelry chain, ball point pen card first hoop, a knife cutting tool parts.

MIM process manufacturing

MIM process requirements and metal powder and a binder, and then at a certain temperature by appropriate methods of powder and binder is mixed into a homogeneous injection molding feedstock, after granulation in the injection molding machine injection forming, the forming blank after degreasing Sintering Densification of the final product.

The MIM machining can be directly formed into complex geometry structure of embryo, through degreasing sintering can reach precision size structure, has good compactness; high density, uniform inner tissue can pass to the following surface treatment to achieve a good finish; mass production with low cost production efficiency to be high.

MIM process manufacturing

MIM process requirements and metal powder and a binder, and then at a certain temperature by appropriate methods of powder and binder is mixed into a homogeneous injection molding feedstock, after granulation in the injection molding machine injection forming, the forming blank after degreasing Sintering Densification of the final product.

The MIM machining can be directly formed into complex geometry structure of embryo, through degreasing sintering can reach precision size structure, has good compactness; high density, uniform inner tissue can pass to the following surface treatment to achieve a good finish; mass production with low cost production efficiency to be high.

MIM Process

The general sequence of operations involved in the MIM process is shown schematically in the following organigram:

The component powders are mixed, together with lubricant, until a homogeneous mix is obtained. The mix is then loaded into a die and compacted under pressure, after which the compact is sintered.

An exception is the process for making filter elements from spherical bronze powder where no pressure is used; the powder being simply placed in a suitably shaped mould in which it is sintered. This process is known as loose powder sintering.

Short Shot in Metal Injection Molding

It is well known for metal injection molding supplier that short shot is a very common defect in powder injection molding process. Today we would like to discuss the reason for short shot during MIM process. Welcome your supplement.

Phenomenon
--material is not completely filled the cavity

Possible reason for short shot in injection molding

l   Inadequate  measurement set

l  injection pressure is too small

l  injection speed is too slow or injection time is too short

l  mold temperature or tube temperature is not enough

l  the back pressure is too low or no back pressure caused screw idling

l  too much release agent

l  Too short  flow distance or bad  illiquidity of material

l  sprue or runner is too small

Burrs in Metal Injection Molding

It is well known for metal injection molding supplier that short shot is a very common defect in powder injection molding process. Today we would like to discuss the reason for short shot during MIM process. Welcome your supplement.

Phenomenon:
Material overflow from mould cavity

Possible reasons for burrs
- measurement set
- injection pressure is too great
-Insufficient clamping force
-mold or feed tube temperature are too high
-Bad liquidity of material
- crystallization rate is too slow
- bad parting line airtight 

Cost analysis of each process in MIM process

MIM applicable materials mainly include: Fe alloy, Fe-Ni alloy, stainless steel, W alloy, Ti alloy, Si-Fe alloy, hard alloy, permanent magnetic alloy and alumina, silicon nitride, zirconia and other ceramic materials.

MIM process longer, many materials processing, in the actual production, if through scientific analysis to know which processes cost is the highest, to improve the key process to improve the efficiency, yield, we can effectively increase the profit, so as to improve the enterprise's own competitiveness, especially in the current Chinese economy has entered a new normal situation, to the enterprise is particularly important.

For the perfect, hard to cut material or difficult to cut the geometry of the complex, casting raw materials, segregation or contamination of the parts, using MIM technology can greatly save costs.

MIM industry are clear, usually, skim, injection molding, mold loss for 3 of the 3 lower costs, the 3 plus up is but the total amount of 10%~15%, only less than after the treatment of 1/3! (of course, according to different products will have different differences).

Reduce the cost of the main direction of:

1) their ingredients, mixing by feeding, but high technical barriers;

2) to improve the yield of the product, use the maximum feeding;

3) the process of improving the process to induce the accelerated removal of the binder, it may greatly reduce the cost of sintering;

4) to strengthen the training, training an experienced, skilled workforce, in order to reduce the number of employees.

The reason is that after the treatment including: sand blasting, to the front, shaping and testing, most of the artificial detection. Artificial detection accounts for a large proportion of the cost