Frequently asked Questions
Metal Injection Moulding (MIM) is a manufacturing process that involves manipulating metal or ceramic powders to behave like a plastic by mixing them with polymer binders to form a feedstock. This feedstock is then used to injection mould net shaped, precision components. Intricate and complex geometries that in the past have been either very difficult or very costly to produce through traditional manufacturing methods can be readily achieved with MIM and at significantly reduced prices and lead-times. Also, detailed features such as serrations, internal and external threads, text and graphical symbols can be moulded into the part, eliminating the need for expensive secondary operations. MIM enhances product quality, reduces lead times and gives rise to significant cost savings of anything up to 50%.
MIM components are available in various materials including: 300 & 400 series Stainless Steel, Stainless Steel 17-4, Kovar, Nickel Iron, Iron, Copper, 100 Cr6, Magnetic Alloys, Hastelloy, Inconel and Ceramic
Our MIM process is now becoming widely accepted as the standard manufacturing technique within a number of industry sectors including: Medical, Aerospace, Automotive, Industrial, Telecommunications, Gas Analysis, Agricultural, and Instrumentation.
The strength and performance of MIM parts are comparable to those of wrought and cast components.
Generally after the sintering stage the theoretical density of the components we produce will be controlled within the range of 95 - 98% dense. To be gas tight, i.e. to have no interconnected porosity, the density of a component needs to be above 91-92% dense. Parts that we make are currently used in gas analysis and hermetic packaging where the drawings have very stringent tolerances on porosity. We can now produce parts with wall sections as thin as 0.5mm with a leak rate of 10¯10 cm3.s-1 (Atmosphere Helium)
Due to the nature of the MIM process, there will be some porosity left in the component after the sintering stage, however, what porosity is left will be very fine and isolated. Even machining or casting will not give 100% dense parts as there will often be inclusions, mainly in cast components.
MIM is most effective for small, complex components in annual volumes of 1000 or more (although if the part is particularly complex and expensive MIM could still be cost effective for volumes of 500 or more).
We are highly experienced in the manufacture of MIM components as we have been a MIM supplier for over 9 years and our Senior Engineers have been involved in developing MIM for over 20 years.
Yes, Metal Injection Moulding is our core business, we are therefore fully equipped to enable us to keep every step of our MIM process in house, all the way from the tool design and build, to the compounding of the feedstock, right through to the final sintered part. This tight control at every stage allows us to manage the consistency and dimensional repeatability of the parts we produce enabling us to supply parts of unrivalled quality.
We are ISO 9001-2000 accredited and we work in accordance with our tight Total Quality Fundamentals. These include Process FMEA to Manage Risk, JEDEC Control System to Eliminate Defects, Production Inspection and Validation Criteria Documented and Statistical Process Control Where Applicable.
Our volume capability is underpinned By: 6 Moulding Machines, 5 Debind Ovens, 4 Sintering Furnaces, In House Polishing Capability, Fully Equipped Tool Room with an AutoCAD System, Mitutoyo Vision Measuring Machine, Various Sizing and Measuring Tools.
Yes, as a supplier we regard ourselves as an extension of our customers business, therefore a close working relationship with our customers has always been fundamental to our business and our high level of customer satisfaction. We offer support and design advice on new and ongoing projects and we maintain a high level of communication between both parties.
Yes, we design the tools in house on our AutoCAD based system and build the tools in our fully equipped, well maintained tool room. The tool comes with a lifetime guarantee so all maintenance and repair is carried out at our cost.
We compound our own feedstock in house. Each mix is custom developed by our metallurgist to ensure it will give us the shrinkage rates required to achieve the parts final dimensions.
Please contact our sales office at: Edige House Thompson Drive Bentwaters Park Rendlesham Suffolk IP12 2TW Tel: 01394 445100 Fax: 01394 445109 Email: sales@egideuk.com