As in manufacturing industry, all companies and enterprises are trying best to produce high quality parts with less production time and lowest total cost. There is no doubt that this is crucial for their final parts production successful. Especially, in this rapid development of new metalworking technology, our clients require more and more metal parts with specific geometries, unique properties and micro size for their new products development or generation products improvement. Metal injection molding is the most effective manufacturing process to accomplish with high volume production at short time.
In ZCMIM, we have professional engineering team to assist you all the way form drawing design to final mass production. Our metal injection molding team will not only decrease your front investment, but also streamline your validation process. In order to improve your parts production process into a automatic way with high capacity.
In MIM manufacturing process, we always recommend high volume production for our customers, there are a few key factor encourage its high return.
Importance of MIM scale production
As in MIM designing, we notice the importance of Design for Manufacurability (DFM), at the same time, Design for Scalability must be considered at product design forefront. Add scalability in previous design enable us to build tooling in advance, in order to satisfy sudden surge production demand, or further design features modifications. With design engineers consultations at part development operation stage, we can easier understand variable element in MIM design, and develop an efficient blueprint for our customers. Finally, we can produce successful market parts with high reputation.
MIM Scale Production Control
In order to deliver quality parts for our customers, we must plan forehead for possible manufacturing disruptions and volume changes in MIM process. It is significant to examine the entire cycle of projects and create detail blueprint. In blueprint planing process, documentation of process variable elements should be the key factor of successful production control. It will focus on the entire process, in order to eliminate loss of key steps control once production volume increases, and adapt with unexpected adjustment. Finally decrease delivery times with excellent quality performance.
Increase Production Volume
In MIM scale production process, scaling technique as Predictive CPK Modeling can be used to increase production volume effectively and efficiently. Tolerances and dimensions are analyzed to identify CPK degree during production process, then sustain the capability we can control in production. All variable element in production process are identified with CPK modeling form feedstock quality and consistency to molding variations and defects. CPK molding will streamline our supply chain and scale our capability rapidly, finally guarantee your parts delivery time.
MIM Project with Automation
There are many metal manufacturing technologies, which can produce metal parts with complex geometries, such as CNC machining, Direct Metal Laser Sintering (DMLS). But for large scale production, MIM is the most suitable way. With automated process, you can easily control production volume no matter high or low, especially scale quickly form low volume to high with limited overhead. Automatic production process will increase production efficiency, decrease material waste, achieve high quality and accuracy in less lead time.
Pressure Sensor Cavity Monitoring (PSCM), as the most popular automated process, will possibly increase parts complexity, stabilize process controls and increase molds cavity. This will maintain strict process control with annual quantity and capacity improvement.
Reduce MIM Scale Cost
Whether MIM is the right process for your project, regardless of design scalability, it is very important to determine production cost in the way of analyzing parts complexity and production time. For example, CNC machining for a complex metal parts with multiple setups, will need more than 3 period, in reason of all separate features need to complete by orders. The machining centers capacity will be limited by their facilities, otherwise, the only way to increase capacity is additional machines or multiple suppliers. This will also give rise to unexpected risk of quality and production control. The distinct benefit of MIM is scaling with same footprint of prototyping, you can add cavitation to exiting molding with reasonable design adjustment, instead of preparing new molds in process. This means you never need additional cost investment for medium to high volume production.
Final scalability consideration
MIM scaling just represent our process management of consistent control in full scale production, it doesn’t mean we have to produce millions of piece a year. Our key of MIM scaling is maintain production and process control with excellent capability.