Metal injection molding (MIM)
was a big winner at the 2009 Powder Metallurgy Design Excellence Awards
Competition, sponsored by the Metal Powder Industries Federation. Two of the
five grand prizes went to MIM parts, while a third received an award of
distinction.
MIM has a bright outlook
because of its opportunities to provide complex designs and strong parts. A
report from BCC
Research projects that MIM will grow globally at a 14 percent compounded
annual growth rate over the next five years.
High-Density Air Nozzle
A 316L stainless steel
compressed air nozzle produced by FloMet of Deland, FL, won the hand
tools/recreation category Grand Prize. The hollow nozzle consists of top and
bottom halves that are molded separately and then laser welded together during
debinding and sintering. Air flow capacity is controlled to comply with U.S. and
European Union machine device noise regulations. The complex part has a density
of more than 7.6 g/cm3, an ultimate tensile strength of 75,000 psi,
yield strength of 25,000 psi and a 50 percent elongation.
Intricate One-Piece Design
An external connector for a
high-performance fiber-optic module won the Grand Prize in the electrical/electronic
components category. The part is a 17-4 PH stainless steel MIM flagstaff nose
or EMI nose shield. The part has a density of 7.5 g/cm3, tensile
strength of 130,000 psi, yield strength of 106,000 psi, an eight percent
elongation, and a 27 HRC as-sintered hardness. The molder, Advanced Materials
Technologies of Singapore, said the intricate one-piece design would have been
almost impossible to produce by any manufacturing process other than metal
injection molding. Secondary operations are limited to coining on the two
latches and the application of a 0.5 micron gold coating for appearance and
corrosion resistance.
MIM Process Provides Undercuts
Parmatech Corp. of Petaluma, CA,
received the Award of Distinction in the hand tools/recreation category for a
420 MIM stainless steel housing block used in a 45-caliber handgun. The part
contains a spring mechanism and provides sliding action with other mechanical
parts. It features wings, undercuts, through-holes and blind holes, as well as
thin and thick cross sections. Formed to a final density of 7.7 g/cm3,
the part has a tensile strength of 261,000 psi, yield strength of 218,000 psi,
and a 48-52 HRC hardness range.
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