How MIM Works
Create the Feedstock : Fig 1 & 2
Mixing fine metal or ceramic powders with organic binders creates the feedstock. The binder 'recipe' is a crucial step of the process in ensuring that a quality component is produced. Because of the importance of this stage we have our own in-house metallurgist who creates custom binder systems to ensure the most suitable feedstock is created for the components tolerance and finish requirements.
Moulding : Fig 3
A custom made tool that has been designed and produced in-house is fitted into a standard moulding machine and the feedstock is injection moulded into it to produce a net shaped 'Green' component. The knowledge and expertise of our in-house tool department is critical as the quality of the final part is as much dependant on the quality of the tool as it is on the feedstock.
De-Binding : Fig 4
The moulded 'Green' component is placed into a low temperature thermal de-binding oven where the binder constituents are vaporised to remove them, transforming the part into a 'Brown' component.
Sintering : Fig 5
The 'Brown' component then reaches its final stage of the process where it is sintered in a controlled atmosphere. Temperatures are taken to just below melting point of the material, allowing menisci to form between the particles. Controlled uniform shrinkage of up to 20% occurs at this stage and the component densifies to its finished size, shape and tolerance parameters.
After sintering, the high density 'White' component has equivalent properties to wrought materials. Furthermore the parts can be heat treated, polished, plated or welded.
Post Sintering Operations
Our experience and attention to detail enables us to produce quality components that don't require costly secondary operations. This is achieved through mould tool development and feedstock manipulation. However when requirements do exceed even our process capabilities we work our clients to develop the most cost-effective solution.
Mixing fine metal or ceramic powders with organic binders creates the feedstock. The binder 'recipe' is a crucial step of the process in ensuring that a quality component is produced. Because of the importance of this stage we have our own in-house metallurgist who creates custom binder systems to ensure the most suitable feedstock is created for the components tolerance and finish requirements.
Moulding : Fig 3
A custom made tool that has been designed and produced in-house is fitted into a standard moulding machine and the feedstock is injection moulded into it to produce a net shaped 'Green' component. The knowledge and expertise of our in-house tool department is critical as the quality of the final part is as much dependant on the quality of the tool as it is on the feedstock.
De-Binding : Fig 4
The moulded 'Green' component is placed into a low temperature thermal de-binding oven where the binder constituents are vaporised to remove them, transforming the part into a 'Brown' component.
Sintering : Fig 5
The 'Brown' component then reaches its final stage of the process where it is sintered in a controlled atmosphere. Temperatures are taken to just below melting point of the material, allowing menisci to form between the particles. Controlled uniform shrinkage of up to 20% occurs at this stage and the component densifies to its finished size, shape and tolerance parameters.
After sintering, the high density 'White' component has equivalent properties to wrought materials. Furthermore the parts can be heat treated, polished, plated or welded.
Post Sintering Operations
Our experience and attention to detail enables us to produce quality components that don't require costly secondary operations. This is achieved through mould tool development and feedstock manipulation. However when requirements do exceed even our process capabilities we work our clients to develop the most cost-effective solution.
| Process Parameters | |
| Maximum Footprint | 2,500mm² | Maximum Length | 100mm |
| Wall Section | 0.2 - 5mm |
| Optimum Weight | < 50g |
| Surface Finish | 0.4 - 1.6µm |
| Working Tolerance | |
| Dimensions | Capability |
| 5mm | +/-0.025mm |
| 10mm | +/-0.05mm |
| 20mm | +/-0.10mm |
| 40mm | +/-0.15mm |
These tolerances are the MIM industry standards but can be improved with secondary operations and mould tool development.
