The Metal Injection Molding (MIM) process
Often times, excellent and complex design solutions tends to fail commercially – but why? Usually the component is finished with labor-intensive technologies to ensure the right profile and structural design, or maybe it is 3D-printed to avoid the post-finishing. This results in high costs of production and the inability to quickly ramp up large volumes. This is where the technology of Metal Injection Molding (MIM) comes into play as shown in the graph below.
Recent
Case studies
European Production of Metal Injection Molding (MIM)
Sintex distinguishes itself as one of the few companies in Northern Europe employing Metal Injection Molding (MIM), a cutting-edge technique revolutionizing component manufacturing. With the majority of our supply chain operations located within Europe, we ensure efficiency and quality at every step.
MIM technology enables us to produce large quantities of components with exceptional intricacy. Our capabilities extend across various industries, including food processing, thanks to the complex geometries and food-grade surface materials of our products.
What sets us apart is our commitment to tailored solutions for each client. We reject the notion of “one size fits all” and instead offer personalized consultations led by our team of experts. By collaborating closely on component design, we optimize functionality and efficiency, delivering superior results for our clients.
Our customized components vary in detail and weight, accommodating a wide range of specifications. Whether it’s small components at a few grams or larger ones weighing between 30-150 grams, our advanced production facilities can handle it all while maintaining fine tolerances. Unlike our competitors, we excel in producing sizable components, meeting demand with virtually unlimited volume.
MIM Differentiators
But our differentiation doesn’t stop there. Our components boast unrivaled corrosion resistance, thanks to our development of high-performance alloys. These alloys enhance durability against corrosion, ensuring longevity and reliability in even the harshest environments. At Sintex, our plant only entails stainless steels.
Furthermore, our components are net shape, eliminating the need for post-processing once they leave our production line, hence ensuring high scalability in the continuous furnaces. This streamlined approach not only saves time but also maintains the integrity of the final product.
Combined with our minimal CO2 footprint, these attributes have garnered high praise from our customers and fostered a loyal clientel base. At Sintex, we are committed to innovation, quality, and customer satisfaction, setting the standard for excellence in the industry.
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Metal Injection Moulding Transforms Pump Components
A ventilation plug for a pump was in the old version produced from rod bar materials in AISI 316L stainless steel with a cold forging process followed by a tread rolling process. The plug had a weight of 54,4 gram.
In collaboration with our customer’s designers, The Sintex MIM-team redesigned the component for the next generation pumps, resulting in a weight reduction to 17 grams. This effort saved 37,4 grams of AISI 316L material for each component produced.
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Grundfos strength requirements met through MIM technology
Earlier, the pump manufacturer Grundfos produced one of its sensor housings in plastic, but more demanding requirements led to the company considering a solution in metal. There was a wish for greater strength because the sensor housing is primarily used for industrial purposes in environments that degrade plastic materials both thermally and chemically
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High strength requirements fulfilled using MIM
MIM technology has given one of our partners a sensor housing in the same geometry as plastic, but with the same strength as steel.
MIM technology has given one of our partners a sensor housing in the same geometry as plastic, but with the same strength as steel.
Earlier, one of our partners produced one of their sensor housings in plastic, but more demanding requirements led to the company considering a solution in metal. There was a wish for greater strength because the sensor housing is primarily used for industrial purposes in environments that degrade plastic materials both thermally and chemically. With the technology behind MIM, Sintex is able to produce a sensor housing with the same geometry as plastic, but with the same strength as steel. At the same time, MIM enables the entire sensor housing to be produced as a single component – in a single process.
MIM was quickly identified as an alternative to plastic, but other metal machining processes were also looked at as mim did not immediately appear to be the most cost-effective solution. Sintex was involved as a competence centre and was able to optimise the design so that the costs of the mim process were offset by savings in the new design, subsequent processing and the additional advantages that a mim component offers.
As an example, it can be noted that the sensor housing was previously installed by means of a retaining plate produced by the traditional PM process. A redesign with a thread at the bottom of the sensor housing has made the retaining plate – and thus its assembly – redundant. This was of course possible due to the increase in strength thanks to the component being produced in steel.
The sensor housing is fitted into a flow pipe that is used to measure flow and pressure in pipe systems. The housing is used to protect and enclose the electronics for the measurements.
How has our partner benefitted from collaboration?
- Greater strength
- Access to chemical and thermal environments where sensors could not previously be used
- Optimised design – redesign of 2 components to a single component
- Less assembly
- More functions
… and not least experience with a first-class technology within powder metallurgy – a technology that is now used by our business partner in several other different areas.
