Metal injection moulding (MIM) has gained a reputation the world over as a reliable, cost-effective way to manufacture intricate metal components at speed. But there is so much more to MIM than just a fantastic price point and adaptability.
Here, in the first of a two-part series, CMG’s Dr Samuel Wilberforce looks at the benefits of MIM in detail.
What is MIM?
MIM is a modern manufacturing process that is used to create intricate parts for a range of uses, from medical machinery to aerospace and telecommunications.
It involves the manipulation of metal powders to make them processable like a plastic by mixing them with polymer binders to create a feedstock – which is used to injection mould precision components.
These parts are then thermally processed to remove the binder system and sintered to a high-density component.
What makes MIM a great choice for high-volume production
- Intricacy
Arguably the biggest advantage of MIM is the ability to make highly intricate parts at scale – achieving both a level of accuracy and speed which simply isn’t available through traditional manufacturing methods.
MIM can achieve a tolerance of less than 0.5%, something other methods could never come close to achieving. That makes MIM particularly appealing to the medical industry, with the parts we create here at CMG being integral pieces of numerous bits of medical machinery worldwide.
- Environmentally-friendly
MIM is considered a very green process when compared to more common methods such as CNC machining. This is because it produces significantly less waste.
Simply put, with MIM you use the exact amount of material you need to create a part – which can easily be reground and manufactured again should you not be happy with the first run. The carbon footprint is also much lower, thanks in part to the reductions in waste.
- Cost-effective
At CMG, our machinery runs 24/7 and requires minimal staff input, helping significantly reduce the costs further.
Once a mould has been created – no matter how complex the design – MIM allows us to create as many as tens of thousands of parts every month. That level of production wouldn’t be possible with other manufacturing methods.
- Choice of materials
Unlike other forms of manufacturing, MIM also allows for the use of different types of metal. This is particularly important when considering that titanium, for example, can be very difficult to machine.
While titanium can be injection moulded, we use a vast array of materials at CMG – ranging from 300 and 400 stainless steel to iron, copper and ceramic.
This is particularly important considering the different benefits and properties certain materials bring, be that strength, durability or low carbon contents.
- The technology continues to advance
One of the most exciting things about MIM is that despite it already being a popular and trusted manufacturing process around the world, it is still in its infancy.
That means that the benefits we have highlighted already are only set to improve over time as further advancements in the technology are made.
If you are looking at moving away from traditional manufacturing methods for your components and would like to learn more about MIM, contact us today.