Design
Principles
Size Range
Tolerances
InjectAlloy®

 


 

 

Click for Quote Form

We have a large variety of powder metal presses and computer-controlled injection molding machines, all built to our specifications.

That gives exceptional range in the types of parts we can produce. But it's our exclusive, custom-built sintering furnaces that really set us apart. Sintering is the most crucial element in both powder metal and MIM production. Our furnaces feature up to 11 precisely controlled temperature zones. And we have furnaces especially built to optimize results for both powder metal and MIM production. Most powder metal and MIM parts producers use belt-fed or batch furnaces. Belt-fed furnaces limit temperatures and, therefore, the available performance properties. Batch furnaces are usually output-limited. Our pusher furnaces mean we offer you both the superior performance characteristics of high-temperature sintering and high production capability.

The MIM process, using multicavity tooling, is well suited for the production of geometrically complex parts in the mid- to high-volume range. MIM can reduce cost when compared with smaller investment castings and discrete machining, and to some extent, with conventional powder metallurgy when significant secondary machining or assembly of the P/M part is required.Metal injection molding typically will not compete directly with drop-off screw machine components, stampings or die castings. However, assemblies made by combining a number of small parts can often be molded as an integral piece by MIM. The process is capable of forming complex configurations and has a degree of geometric freedom equivalent to that of injection molded plastics or castings.
 

Secondary Operations

Any powder metallurgy process creates some porosity. MIM minimizes total porosity and typically limits interconnected porosity (that porosity connected to a free surface) to less than 0.2%, regardless of the product's percent of full density. This means standard coloring and plating techniques can be used without resin impregnation. Oil impregnation and copper infiltration are not used with MIM. When heat treated, parts can be case hardened to closely controlled case depths equivalent to wrought material. Other metalworking techniques such as drilling, tapping, turning, grinding, and broaching work well with MIM. All parts are barrel finished unless otherwise specified. These guidelines are not absolute, and are influenced by a number of factors related to part design.

Surface Finish

Surface finish of MIM parts is approximately 32 RMS (0.80 micrometer), appreciably better than most investment castings. However, profilometer readings may be affected by residual porosity and are subject to interpretation. The method of measuring surface finish should be agreed upon by both the customer and vendor. The surface of MIM parts can be improved by conventional processes such as grinding, lapping or burnishing.