INDO - MIM Shaping the future of Metal Injection Molding

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CONTENT
Metal Injection Molding (MIM) Materials Portfolio: Case Studies MIM Design Guidelines Mold Concepts Equipments & Indo-MIM Group Details

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Metal Injection Molding

Mass production of complex shaped metal parts Quantities from a few thousand to millions

Can bring significant cost reduction v/s machining

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MIM Process Flow

20% Shrinkage

Compounding

Finished Part

Molding

Debinding

Sintering
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MIM Process Flow

Fine metal powder is mixed with a polymer binder. This mixture is granulated to form feedstock Feedstock is heated to form viscous slurry and injection molded to form green part. Granules

Injection mold

Part of the binders are removed through solvent de-binding to get brown part. The brown part is densified through sintering to get finished part.
Solvent

De-bind

Pre-sinter Sinter
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Micrograph-Process flow in MIM

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Increase in Neck Size - Sintering

Temperature
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Typical Materials Processed

Low alloy steels Low C, case hardening 4600 series (Fe-Ni-Mo)

Med C, through hardening

High C, through hardening Stainless steels Austenitic Martensitic

4630-4650 (Fe-Ni-Mo-Cr)
52100 304L, 316L 420, 440A/B/C

Precipitation hardening
Ferritic Tool steels Die steels High speed steels Non-ferrous Tungsten Titanium Specialty and superalloys Magnetic Electronic packaging High temperature

17-4PH
430 S-7, D-2 M-2, T-15, 10-V Fe+ Cr+ Ni CP Ti, Ti6Al4V Fe-Si, Fe50Co, Fe50Ni Kovar, Fe-Ni (Invar) Co-Cr (F-75), Inconel, Hastelloy, HK-30, 310Nb, Tribloy
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MIM v/s Solid Steel Tensile Property

1600 60

UTS (Mpa)
1400

YS (Mpa)
1200 1000

50

40

800
600 400 200 0

30

Mpa

20

10

Note: MPIF STD 35 used for MIM materials & ASTM Standard used for Wrought materials
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% Elongation

Elongation (%)

What MIM Offers

Complex shape making capabilities

Good surface finish and

dimensional tolerance

Cost effective
production solutions

MIM
Suitable for Small to very

Metallurgical alloying
advantages
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high volume productions

MIM Positioning

Machining

Casting

Unit Cost

Press and

sinter

MIM
High
High Complexity
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Low
Lower Per Unit Cost

Medium

Complexity

Applications
AUTOMOTIVE MEDICAL DEVICES

INDUSTRIAL

CONSUMER GOODS

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Shape Making capabilities - MIM

Dimension: +/- 0.5 % of the base Surface finish: 0.8 - 1.6 Ra Minimum wall thickness: 0.3 mm Minimum hole diameter: 0.5 mm Density: 96 99 % of theoretical density Weight limit: 200 grams Size limit: 150 mm

Hexagonal, square or splined holes, even at angles to each other feasible

Irregular profiles making the geometry complex can be easily manufactured Extremely high cost savings V/S machining for complex shaped parts
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Case Analysis

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Case Example - Braking System Part

Application : Auto Slack adjuster Critical requirement : High wear resistance Constraints: Welding of half circle profile to the cylinder

Hole forming
Problems faced: Less strength at welded features Burrs due to hole forming Solution: Component made in MIM, by avoiding welding Cost savings more than 40%

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Case Example - Automotive part

Application: Automotive Critical requirement: Size , Weight and cost reduction Constraints: PM Process+ Machining operations Larger part dimension due to lower material strength Solution: Redesigned the part to smaller ,size ,weight and all the features by MIM process at lower cost
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PM Part

MIM Part

Weight reduction Case Example

PM Flange + Machined Shaft +

One Piece MIM Part

Welding Part

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Case Example
Customer
A leading US-based medical device company

The Challenge Highly complex geometries to be manufactured cost effectively through machining Need for expensive burr removal operations Distortion in Sintering in MIM Value Delivered Net shape achieved in MIM with no burr / loose materials formation Distortions avoided with the use of special ceramic setters

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Case Example Components for Hearing Aids

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Case Example Components for Hearing Aids

Application : Components for hearing aids like metal hook, tube element Critical requirement :

Material with high density for good sound damping ability and good corrosion resistance Good dimensional consistency and close tolerances for proper assembly and function Good surface finish with various surface textures for aesthetic appeal Competitive cost of manufacturing Clean manufacturing process to meet the specified cleanliness level in the final component

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Components for Hearing Aids

Previous Manufacturing Method: The parts were manufactured previously by CNC machining in two halves and glued together

MIM Solution:

MIM has incorporated all of the features and geometry of the part in a single piece design avoiding secondary gluing operation
The material used were MIM SS 316L and other tailor made materials which have high good sound damping ability and good corrosion resistant MIM can produce medium to high volume requirements at competitive price with required surface texture and better surface finish
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Capabilities
3-D complex shaped profiles Tolerance within (+/- ) 0.5 % of base dimension Surface finish within 1.2 Ra

Limitations
Maximum part weight 100 gms.

Maximum length 150 mm Maximum wall thickness 8 mm Higher per unit cost at low volumes

Volumes from thousands to

millions Quick prototype & ramp up

Only high melting alloys

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MIM DESIGN PRINCIPLES

Uniform wall thickness

Coring ( Mass reduction)

Drafts, Holes, Corner breaks & Fillets Undercuts - External / Internal Knurling, Lettering & Logos Staging surfaces MIM Features Mold Layout & Details
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UNIFORM WALL THICKNESS

In MIM, making uniform wall thickness is desired for higher precision, more repeatable dimensional capability & improved aesthetics.

Uniform wall thickness

If however, variable wall thickness cannot be avoided, a gradual transition between differing wall thickness should be provided and every attempt should be made to avoid abrupt transitions.
Transition ratio if different wall thickness cannot be avoided
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CORING / MASS REDUCTION

Unlike machining, removing excess mass gives an opportunity to reduce the amount of the expensive fine metal powder required for the part. This helps in minimizing the final cost

Before Coring While coring, uniform wall thickness should be maintained.

After Coring
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DRAFTS, CORNER RADIUS & FILLET

Draft is required for smooth ejection of the component. This also helps in avoiding unnecessary stress created on the Green part. The typical draft angle required is degree to 2 degree per side for both inside and the outside walls.

MIM can produce corner radius and fillets from the mold.
Typically, corner radius should be kept larger

than 0.2 mm. Internal and external corner radius less than 0.2 mm will induce stress concentrations in the part and will be difficult to fabricate in the mold.

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EXTERNAL & INTERNAL UNDERCUTS

External undercuts can be readily produced

Internal undercut that can be formed by a slide can be readily produced Internal undercut that cannot be

produced by a slide requires a

collapsible core and provides challenges for the MIM process
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KNURLING, LETTERING & LOGOS

KNURLING

LOGO

LETTERING
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SINTERING SURFACE & METHODS

While the parts are shrinking, during thermal sintering, the forces of gravity and friction (from shrinking) may distort the parts if they are not adequately supported.

Sintered Part

Special staging blocks

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MIM PART FEATURES

Ejector pin marks

Flat land on external thread

Cavity ID Parting Line Gate mark

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MOLD LAYOUT & DETAILS

Slide closed condition

Four Cavity Mold Slide open condition

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Three Plate Mold

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Equipment - MIM

Molding Bay Batch Sintering

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Equipment - MIM

Continuous Furnace
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Advanced Testing Equipments

Micro Fine Focus X-Ray

100 X Magnified Image

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Mold Flow Analysis

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Advanced QC Vision System

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White Room Manufacturing & Inspection

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ISO Class 8 Clean Room Assembly & Packaging

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Group Companies
Aerospace part machining

Metal Injection Molding

INDO-MIM Group

Precision Investment Casting

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Indo-MIM Fast Facts

Independent company Starting of Investment casting Largest MIM company

1997

2001

2006

2010

2011

2011

2012

Start of Joint venture

Starting of second plant

Aerospace division

Medical facility, Titanium Injection, Ceramic Injection molding

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Manufacturing Facilities
Plant 1 (Hoskote, India) 11,000 sq meters Short to med run production Tool Library & Maintenance

Administration

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Manufacturing Facilities
Plant 2 (Doddaballapur, India) 22,000 sq meters High volume production Tool room

Plating
Precision machining

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All round capability

In-House mold design with Pro-E and Solid Edge as the base CAD platforms. In-House world class tool room produces 40+ molds per month 83 CNC molding machines and the number grows every quarter.

We are the only MIM facility in the world with fine focus X-Ray to detect
defects on the green part right at the molding stage. 16 micro-processor controlled sintering furnaces including continuous

furnaces provide us largest cubic feet of sintering capacity in the world.

In-house heat treatment using vacuum furnaces and sealed quench furnaces. Polishing and plating facility for cosmetic components. CNC finishing facilities.

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Integrated MIM Manufacturing

Design + Tooling

Material Compounding
Injection Molding De-binding + Sintering Secondary Operations Quality System

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Secondary Operations
Heat treatment

Hot isostatic pressing

CNC milling + Turning Grinding + Lapping Tapping + Threading Polishing, Micro-blasting

Plating & Coatings (RoHS Compliant)

Assembly + Integration

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Quality System
ISO 9001:2008 & ISO/TS 16949:2009 (registered by UL-DQS) ISO 13485:2003 certified (registered by UL-DQS) Dimensional inspection Full compliment of measurement equipment including CMM + vision system Laboratory Metallographic, chemical and physical testing (in house and through sister company Shiva Analyticals) In house fine focus X Ray

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World class equipments

TS 16949 certified since 2002 Equipped with world class inspection equipment Fine Focus X-Ray at molding Micro-Hardness tester, metallurgical microscope, UTM at Lab Rheometer, Pycnometer density meter

Corrosion testing,
Computerized traceability system SPC starts right at product development

stage

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New Materials Developed

Tribaloy T400 Medical alloy Ceramics High wear resistance Implant alloy F75 High Temperature applications, Medical implants, Electronics Counter weights, Electronic sensors Medical alloys Aerospace Specialty and superalloys Magnetic Electronic packaging High temperature Cobalt Chrome alloy Cobalt Chrome F75 Alumina, ZTA ZTA Tungsten heavy alloys CP TI, Ti6Al4V CP TI, Ti6Al4V Si-Fe Kovar, Fe-Ni (Invar) Co-Cr (F-75), Inconel, Hastelloy, HK-30, 310Nb

Refractory alloys Titanium

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Indo-MIM Vision
To be the worlds leading producer of engineered products and systems by exceeding our customers expectations on Quality, Delivery, Cost and Service.

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Contacts
Headquarters & MIM Operations:
No 45,(P) KIADB Industrial Area, Hoskote, Bangalore 562 114. Tel: +91 80 2204 8800/2797 1418/2797 1416 Fax: +91 80 2797 1624 Email: infohq@indo-mim.com

EUROPE:
Indian Business Center, Oskar Lapp Str.2 70565 Stuttgart-Vaihingen, Germany Tel: +49 173 65500242 / +49 173 65500243 Fax: +49 711 65500241 E-mail: infoeu@indo-mim.com

MIM & Finishing Operations:

#45[P], KIADB Industrial Area, Doddaballapur, Bangalore 561 203 Tel: +91 80 763 0533/ 763 0532 Fax: +91 80 2763 0532 Email: infohq@indo-mim.com

USA:
214, Carnegie Center Suite 104, Princeton, New Jersey 08540 Ph: 734-327-9842/734-327-9872/609-651-8238 Fax: 734-327-9873 E-mail : infous@indo-mim.com

IC Operations:
Gowri Ventures Pvt.Ltd. Plot # 62B (Part II), APIIC Industrial Park, Gajulamandyam, Renigunta 517 520, AP Tel: 91. 9390845662/63/64 & 65 Email : info@gowri-ic.com

China :
11F Aurora Plaza, No. 99 Fu Cheng Road Pudong New Area 200120, Shanghai Tel: +86 (0) 21 6058-9206 Fax: +86 (0) 21 6058-9376 E-mail: infocn@indo-mim.com

Trkiye :
Tel: 0533 815 60 11 E-mail: osman.k@indo-mim.com
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Thank you

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