Metal injection moulding is an innovative technology widely used in various industries. It helps in transforming large metal sheets into small sheets in large volumes. The process is similar to plastic injection moulding. Injection moulding company in India prefer the metal injection moulding process for various reasons. It is mostly used for the manufacture of small or complex metal parts like surgical tools, cell phone components. Here you can find a detailed overview of the metal injection moulding process. Read to know the significant benefits of metal injection moulding.
Overview Of Metal Injection Moulding Process?
Metal injection moulding is similar to the plastic injection moulding manufacturing process. The only difference is the use of metal powders along with plastic materials. Injection moulding company uses metal and polymer as raw materials for this process. This is referred to as feedstock. The following are the types of metal used in the metal injection moulding process.
- Stainless steel
- Copper alloy
- Nickel alloy
- Cobalt alloy
Here are the detailed steps involved in the metal injection moulding process
Preparing feedstock: This is the first step in the metal injection moulding process. Here the polymer and metal mixture is prepared. The mixture is then granulated into a fine powder. The final feedstock contains 60% of metal powder and 40% polymer. The polymer acts as a binding agent.
Injection moulding cycle: This is the second step where the molten feedstock is fed into the mould cavity. It gets cooled and takes the shape of a mould. It is called the green part. The Injection moulding companies carry out metal injection moulding using machines used for the plastic injection moulding process. The mould cavities are made large to perform this cycle.
Debinding: This is the next step in metal injection moulding. Here the polymer is removed from the moulded metal. The solvent debinding and thermal debinding process help in removing the polymer present in the green part. The brown part is the outcome of the above process.
Sintering: This is the final step carried out in the metal injection moulding process. In this step, the brown part is placed in a high-temperature furnace. It removes the pores and shrinks the mould. The finished part is of high density and helps in creating high tolerant industrial components.
Why do Injection Moulding Company Prefer Metal Injection Moulding?
Metal injection moulding(MIM) is popular for various reasons. Injection mould company prefer this manufacturing process to produce complex and tiny products. Here are the reasons for the wide use of metal injection moulding.
It is Cheap: The manufacturing cost incurred is quite less compared to the traditional manufacturing processes.
It is Flexible: It is a highly flexible process. Small and complex parts can be manufactured at ease. Complicated shapes can also be created through this method. The scale of production can be managed easily. It is possible to use different types of materials in metal injection moulding.
Ideal For Mass Production: It helps in manufacturing different complex parts in large volumes in less time. This makes it suitable for mass production in various industries.
Less wastage: The wastage produced in this process is quite minimal compared to other traditional manufacturing methods. Maximised material usage helps in minimising waste.
It is Consistent and Reliable: This manufacturing process is quite reliable. Precise components can be manufactured. The final product is consistent and uniform.
It is Resistant and Durable: It is possible to manufacture highly resistant end products. It posses good mechanical properties. This makes the manufactured parts highly durable.
The above influences injection moulding company to undertake metal injection moulding processes.
Applications Of Metal Injection Moulding
There are numerous applications for metal injection moulding techniques.
Automotive Industry: Metal injection moulded parts are mainly used in the automotive industry. Complex and high strength engine parts are mainly manufactured using the metal injection moulding process. Gearboxes, steering systems, turbochargers, rocker arms, shift levers are the other automotive components manufactured through the MIM process.
Aerospace Industry: Superalloy materials manufactured by metal injection company are used in aero-engine applications.
Healthcare Industry: The metal injection moulding process plays a key role in the healthcare sector. It is widely used in the manufacture of highly precise surgical instruments and high-quality dental implants. Read More