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Production of complex geometries using metal injection molding (MIM)

Plansee is the partner of choice for metal injection molding of refractory metals. We've been innovating with molybdenum and tungsten for 100 years.

Metal injection molding, or MIM for short, has become a competitive manufacturing process for precision components over the last decade. MIM is used to produce components with complex geometries such as undercuts, while components can also be produced in large quantities close to the final shape or with a true final shape – thereby saving resources and costs, and guaranteeing outstanding mechanical properties.

Be it in machining technology, medical technology, the electronics, security, and watchmaking industries or in sheet metal processing – metal injection molding is employed in a wide variety of industries. And Plansee covers every aspect of the MIM process: from powder to feedstock production, from tool manufacture to quality control of the finished components, our experts deliver absolutely everything in-house.

The advantages of metal injection molding at a glance:

  • One-stop-shop for product design, construction, and simulation

  • Capacity for complex geometries 

  • Small batch and series production

  • Cost optimization

  • Outstanding component precision

  • Repeat accuracy

Production of the tool

From the idea, to the simulation, to quality control

Our experts at our sites in Austria and China provide the support you need from the outset. Based on your individual requirements, they check feasibility and assess whether the desired component can be manufactured using the MIM process. The component is optimized if necessary. Using the finite element method (FEM), our design engineers create the tool design based on simulations. The injection molding tool is then produced using state-of-the-art production equipment, such as milling, eroding, and grinding machines or manual polishing. As well as performing the usual quality checks, such as dimensions and surface condition, we also use our injection molding systems to test the tool function; series production only begins after a functional test indicates everything is working flawlessly. Once installed in the injection molding machine, the injection molding process can begin. 

FEM

Tool design based on simulations (FEM) 

Milling the injection mold

Milling the injection mold

Die sinking

Die sinking

Grinding

Grinding

Wire cutting

Wire cutting

Manual polishing

Manual polishing

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Production of the component

The optimum feedstock for your component 

Our experts precisely tailor the granulate (also known as feedstock) to your individual requirements. Depending on the requirements, it consists of pure molybdenum, tungsten, tungsten heavy metal or their alloys, as well as plastic as a binder. The feedstock contains between 40 and 60 percent metal by volume.

The injection molding process

The feedstock is then injected into the mold at a temperature of 100 to 200 °C and very high pressure of up to 2,500 bar. Heating the feedstock melts the binder and presses the plasticized material into the cavities. In this automated process, up to 30 cavities can be filled simultaneously. This makes the MIM process highly suitable for series and mass production, as it stands out for its efficiency, repeat accuracy, and precision. At the same time, the process ensures that the components have the same weight.  

Debinding and sintering

Once the component has cooled down, the injection mold opens and the green compact is removed. During the next step, this green compact is debinded and sintered. Debinding removes the binding material from the molded component before sintering can take place. The component geometry and the chemical purity of the material are retained. The green compact is heated in a sintering furnace under a protective gas atmosphere, at a temperature of >1,500 °C. 

Quality control

Trade fairs

Debinding and sintering give the component its excellent material properties and a material density similar to that of the conventional manufacturing processes of pressing and sintering.

The components must then undergo metallurgical quality control in our own test laboratory, as well as a dimensional and visual inspection. Because Plansee products satisfy the highest standards in terms of extreme material purity, excellent wear resistance, and optimum product quality.

Video

Watch the video to discover why Plansee is exactly the right partner for metal injection molding of refractory metals:

Sustainability

Sustainability in the MIM process

We use our innovative power to help our customers manufacture sustainable products. Components manufactured using the MIM process deliver the following advantages:

  • Material efficiency: Netshape and near-netshape components save resources as they are manufactured close to the final shape, therefore producing little to no material waste.
  • Recycling: Excess molybdenum and tungsten material is fully reused.
 
  • Smaller carbon footprint: Our machines are powered by green electricity.
  • Energy savings: Fewer processing steps are required, which also saves costs and energy, and reduces carbon emissions.
  • Sustainable raw materials: We employ a wide range of measures to ensure that we only source raw materials from socially, ethically, and ecologically sustainable sources.
Contact
Sounds interesting? Then please get in touch with us:
  • Markus De Monte

    Markus De Monte

    Manager Precision Tooling

    +43 5672 600-2768