Once determine whether your parts is fit for metal injection molding process. Part size is the first critical factors. As the most frequent question, “ How large parts can you create byMIM technology?”. The quick answer in most case is under 200 grams. But, in our professional design and evaluation process, it is important to realize the parts size impact final MIM final cost and efficiency.
Part size will never be limited by MIM process, but form the mold size capacity. Normally, the molds has stationary size, once parts size are larger, the less parts numbers will be take up in molds. We can consider molds or tools as one sheet of paper, which has accurate size. When we injection molten MIM materials for required geometry, larger size will fit less cavities than small size. This means that, we can add 10 to 20 cavities in one sheet while only 4 for large size design. For final production quantity of 10,000, smaller size will be more production efficient than large size.
The level of component complexity will dictate which manufacturing process is best suitable for mass production, in order to guarantee production efficiency. While our normal capacity is less or equal to 200 grams, if parts are too large and complex with typical machining requirement. Metal injection molding process is the most economic way. In order to truly utilize MIM process, Design for Manufacturing (DFM) is the best practice guideline to follow, we ensure final MIM parts never require expensive secondary operation, or just simple process in final sintering process. This will reduce most of component cost, in addition with less cycle time.
MIM feedback is inherent more expensive than average metal material, which can be custom with special property requirement. There is no doubt that MIM material cost play a important role in MIM manufacturing process, less material usage determine less cost. In ZCMIM, we optimize our MIM parts design with minimized weight requirement, in addition no negative effect on parts performance. In this case, we only utilize as little material as possible to create final component structure. With MIM process, you can add any complexity on your MIM parts without any additional material. However, traditional metalworking process like machining or die casting will result in lots of scrap and waste. In some cases, we need to consider the production possibility of traditional technology in complex structure design.
ZCMIM are able to produce any required parts for our customers. Once your designing parts is larger than 200 grams with complex structure requirement. In consideration of economic and production capability, ZCMIM will evaluate our MIM technology to provide the most cost effective alternative then other casting process.
Metal Injection Molding is capable of achieving intricate features, it improve final MIM geometries design freedom. You can add functional features like dovetails, slots, undercuts, fins, internal and external threads, or curved surface to your parts design. In reason of MIM utilize injection forming technology, so it can produce unique cylindrical structure with greater length to diameter ratio than other traditional casting technology.
In MIM manufacturing process, molding, debinding and sintering have strict operation guidelines, which regarding mass loading for each batch size, in order to remove binder material at proper and precise rate. For larger and thicker parts, it will need more furnace space and time to debind and sinter. Consider of process cycle cost and time, which meas more cost in final parts production. ZCMIM engineering team has excellent experience in MIM design and production process, we will modify your design to increase final parts production time. Thin wall and minimized MIM material usage will optimize your part for metal injection molding process.
MIM provides a cost-effective solution for small complex component, which would need expensive secondary operation by other metalworking method. With MIM technology advantage, ZCMIM supply widely application in various industries, including electronic, medical, automotive and other industrial tools.
Free MIM Design
As in traditional metalworking process, design limitation is a critical issue in designing process. Consider of practical manufacturing process and actual producing machine, all these limitation always affect final part physical and chemical performance. In MIM design, engineers are able to have more freedom to create parts geometries, utilize material effectively for function and strength requirement, eliminate unnecessary post-operation. MIM technology encourage metalworking in a high level of complex shape with less material usage.
MIM provide lower cost solutions for numerous industrial applications comparing to traditional metalworking technologies. Although parts size is not the necessary driving factor, it is definite most critical factor of consideration. Once you need small, complex part with higher strength requirement in large volume production, your project will be well benefit form design freedom and cost-effective solution of MIM process.
If you are interested in MIM process, contact our professional engineering team. We will cooperate with your through whole MIM manufacturing process, and recommend all benefits specific to your unique project.