Metal Injection Molding

MiMfactories / Devision of Rockleigh Industries Inc. uses the latest wire EDM technology which is fully integrated with CAD/CAM. Using this technology, skills and experience we deliver a complete manufacturing solution for every project and application.

Our services include prototyping, design, in-house tool production, wire EDM, specialist tool transfer service, high-quality manufacturing and logistics. We specialize in pressed metal parts with tolerances as low as one micron. Press from 5 tons to 160 tons.

We do selective plating, metal finishing, de-burring, polishing, degreasing and heat treatment. Our in-house tooling facility manufacturing led frames and other metal components. Rockleigh Industries are specialists in complex materials and hard metals to manufacture stainless steel parts. Stainless steel stamping project. High-speed insertion or welding of precious metal contacts.

Metal Injection Molding works similar to the other injection molding processes – powdered metal is combined with a binding material and then injected into a mold where it’s left to form and curate. The end result is a metal part. The process is ideal for the short and long-run production of metal parts, especially those that are smaller in size and more detailed in terms of properties. Here’s a closer look at the MIM process:

• Mixing and Granulating: The first step in the metal injection molding process is determining the material and feedstock that is going to be used to create the parts. (For more on material range, see the section near the bottom of this article.) Generally, this consists of fine powdered metals – a powder that is fine enough to create the features that are necessary. After the metal powder is determined, it’s mixed with a thermoplastic binder (often which takes up 40 percent of the total feedstock), heated so that the metal grains bond with the binder and then fed into the injection molding machine.
• Molding: The next step is the molding process, where the material is again heated and then injected into the machine for the molding process, which is the point where the part is created.
• Binder Removal: After the part is ejected, the next step is to remove the binder. That’s because the final part is about 20 percent larger than the intended end part. Hence, in order to get it to actual size, the binder needs to be removed.
• Sintering: The final step in the process involves sintering, where the remaining binder is removed from the part and the metal is fused to create the part, the end result being a net shape or close to net shape final part. Further post-sintering operations may also be necessary to properly create the final part, which can add some further steps and complexities to the process.

All in all, MIM is comparable to creating products from bar stock metal, both in terms of tensile strength and design capability. Here’s a further look at the metal injection molding process and whether it’s the right production process for your MiMfactories™ part run.

For more information on MiMfactories™ metal injection molding and to determine if MIM is the best process for your part run, contact one of our specialists today.