Metal Injection Molding

Metal injection molding (MIM) combines the use of shaping advantage of injection molding technology and plastic injection molding to facilitate the production of small, complex-shaped metal components with outstanding mechanical properties. With our deep expertise in MIM technology, we excel in tackling even the most complex production hurdles.

From intricate designs to high-strength components, we offer a comprehensive approach that spans from concept to final product. Trust in our MIM service to efficiently address manufacturing challenges and provide you with innovative and cost-effective solutions.

MIM Applications

MIM excels at applications that require shape complexity and superior properties such as high strength, excellent magnetic permeability, good creep resistance, corrosion resistance and thermal conductivity. Our material portfolio includes a wide range of materials such as carbon steels, low alloy steels, stainless steels, low thermal expansion alloys, non-ferrous metals like tungsten and copper, super alloys like inconel, F75, MP35N, Nimonic 90 and Nickle-Free Stainless steel.

Benefits of Manufacturing with AMT

Combining our MIM technology, material innovations and engineering expertise over the past 30 years, AMT is able to offer innovative solutions such as In-Coring®, bi-material integration, thin-wall capability, etc. Find out more about our innovative MIM applications here.

Although MIM technology is most ideally used for high-volume production, we have adapted to serve in high mix, low volume production. This is because of our focus to serve in the medical industry. MIM technology is ideal for mass producing components used in robotic surgical systems. These robotic surgical systems typically have end-effectors such as clamps, graspers, staplers, needle holders, etc, which are of very complex geometries and shapes.

Our Metal Injection Molding Process

01. Mixing

Metal/ceramic power is mixed with polymer binder to form the feedstock.

02. Injection

The feedstock is molded to form the desired geometry known as green part.

03. Debinding

The polymer binder is removed from the green part by a debinding process to form the brown part.

04. Sintering

During sintering, the brown part shrinks and densifies into a net-shape solid component.

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Innovative Applications

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Robotic Surgical Components

The MIM technology is ideal for the mass production of components used in robotic surgical systems. These robotic surgical systems typically have end effectors such as clamps, graspers, staplers, needle holders, etc, which have very complex geometries and shapes.

As such, an innovative and creative MIM process had to be introduced in manufacturing to ensure the part integrity. Using the MIM manufacuring technology not only reduces manufacturing cost, but also allows for these parts to be produced in large volumes (over 200,000 pieces per month). This is especially cruicial for end effectors used in single-use devices. Similar applications include MIS endoscopy, surgical power tools and life science systems.

Complex Inter-Connecting Channels

The MIM technology is ideal for the mass production of components such as this EPR Flow Block used in Gas Chromatography (GC) Systems. This highly complex part, with multiple through holes and inter-connecting right-angled internal channels, challenges the MIM technology.

Using an innovative manufacturing process, the dedicated internal channels prove critical in managing gas flow to and from the five ports on the parts without any leakage. With this, AMT is able to help the customer overcome their challenge and mass produce these complex geometry parts efficiently and cost-effectively. AMT was awarded the MPIF Grand Prize in 2018 for this innovation. Read about it here.

In-Coring® - Creation Of Complex Internal Channels

AMT has perfected the innovative use of our In-Coring® process to manufacture metal and ceramic parts with undercut features. This innovative application allows the designer to create a single part with internal channels and undercut features without an assembly process.

Thus, the designer is able to enhance the product’s performance while achieving cost savings through mass production. A good example is this One-piece Nozzle used in the automotive Selective Catalytic Reduction (SCR) system. It was awarded the MIM Grand Prize by MPIF in 2015 as well as the EPMA Award in 2018.

Bi-Material Components

AMT is capable of co-injecting two different materials to form an integrated two-material component. By using this innovative application, AMT can integrate hard & soft metal or magnetic & non-magnetic metal materials. By co-injecting the 2 materials together, interlocking features can be incorporated in the part, thus eliminating costly assembly operations. The product’s performance can potentially be enhanced as the two materials are manufactured as a single component.

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Integration Of Components

With MIM, multiple individual pieces can be integrated into a one-piece complex geometry component. This relieves the constraint on the designer, allowing him to focus on the functionality and performance of the product. Using this innovative strategy results in a design with better product performance, reduces part count and achieves overall cost savings. One such innovative application is the integrated component that was awarded the MIM Grand Prize by the MPIF in 2000.

Thin Wall Capability

Using innovative solutions, AMT was able to mass produce complex geometry components with very thin walls. Dealing with wall thickness of below 0.3 mm in the MIM process, our engineers had to manage distortion, shape retention, material integrity and all the dimensions during the sintering process. It was a great challenge but we finally succeeded in the mass production of this part, which won us MPIF’s Year 2002 Award of Distinction.

Hermetic Kovar Housing

This 105mm (4.14in) by 105mm (4.14in) by 1.5mm (0.06in) fiber optic MIM Housing is made of Kovar. Kovar is an expensive material with high nickel and cobalt composition, making it difficult and challenging for conventional machining. This MIM Housing defies the conventional “acceptable size”, enabling it to meet specific dimensional and hermetic requirements as well as minimize material wastage, thus achieving significant cost savings. It was awarded the Year 2003 Award of Distinction by MPIF.

Metal Injection Molding