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Metal injection technology

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米国で特許を取得した、キャステムの独自技術。

Recently, products such as information equipments, electronic and medical devices have been downsizing with technical advances, and those parts for such devices are becoming more and more complicated, requiring higher accuracy.
CASTEM has predicted this trend and developed MIM technology in house, and received U.S. patent in 1991. Since then, we've been pursuing the potential of MIM, manufacturing various parts that can only be made by MIM. We keep focusing on the improvement of our technology to satisfy the increasing demand.

Smooth surface and high accuracy can be attained by MIM without multiple processes required for precision casting, such as gate removal, plane processing, and polishing.

Smooth surface and high accuracy can be attained by MIM without multiple processes required for precision casting, such as gate removal, plane processing, and polishing.

 

What is "Metal Injection Molding?"

• Process Flow
Design Next Die/mold making Next Injectin Next Debinding Next Sintering Next Machining Next Inspection Next Shipment
Metal powder,Organic binder,Combining(compound making process) Metal powder and Organic binder Next Combining Injection Debinding Sintering
 

Mix fine metal powder and binder to make feedstock. Then inject the feedstock into a mold cavity to form the metal part.

Click to watch MIM process
 

• Features of MIM
MIM features a smooth surface that is essential for a fine finish to cam gears and knurled parts.

MIM features a smooth surface that is essential for a fine finish to cam gears and knurled parts.

Small holes, irregular shaped holes and blind holes can expect a highly accurate finishing.

Small holes, irregular shaped holes and blind holes can expect a highly accurate finishing.

 
MIM is suitable for a production of small complex metal parts with flexible designs.

MIM is suitable for a production of small complex metal parts with flexible designs.

The performance of our MIM products will increase as it gets smaller and more complex.

The performance of our MIM products will increase as it gets smaller and more complex.

 
 

CASTEM's Metal Injection Molding

• Strength

MIM

Density is more than 95%, and the mechanical strength is high with independent spherical pores.

Traditional sintering

Density is approximately 88%, and the mechanical strength is inferior with many pores existing in the grain boundary.

 

MIM products have the same level of torsional and bending strength as welding products.
(Picture : SUS304 parts)

• Lot Size

Lot

We are capable of handling small to large lot size orders, from 10pieces to more than 10,000pieces per lot. Low cost molds are exclusively available for small lot production less than 3,000pieces.

Die/mold

With our own die mold factory, we can make 70 die molds per month.
We are dedicated to achieve short term delivery and to handle design changes at the lowest cost.

Materials

There is a wide range of applicable materials, including SCM, SKD, stelite, in addition to popular MIM materials(FeNi, stainless, etc.)

Sintering Process

High speed debinding and sintering is carried out to prevent change in quality and shape, using the most suitable condition for each material, such as vacuum environment, reduction atmosphere, inert atmosphere, and high pressure ambience.

Post Processing

Our integrated production system includes processes such as precision machining, heat treatment, plating, etc.

Others

Our MIM technology has been improving steadily, since all MIM processes has been developed in house. (Received a U.S. patent in 1991)

• Materials

Stainless steel

SUS304
SUS316L
SUS630(17-4PH)
SUS440C

 

Structural steel

SCM415
SNCM439
FE4%NI

 

Tool steel

SKD11
SKH57

 

Cemented carbide

D3

 

Special metal

Kovar

 

Titanium

Pure titanium

 
 

その他

• Designs
1. Weight saving

MIM is unsuitable to make thick-wall parts, however, cost reduction and quality improvement is expected by shape optimization.

2. Corners

Corner shaping
Sharp corners and edges(above A) can be formed by MIM, but from the strength point of view, (B) is more preferred, and (C) is even more favorable.

3. Draft angles

Draft angles are not essential for MIM. However in some cases, draft angles can reduce the production cost.

• Potential and Practicality of MIM
1. Hole size
Size of hole
Hole diameter D(m/m) Length (m/m)
0.1 - 0.3 10*D
0.3 - 1 20*D
1 - 3 30*D
3 - 40*D
 
2. Insert molding
MIM parts inserted in zinc die casting

Because MIM products have high dimensional accuracy, production cost can be reduced by insert molding with products made of different materials or different processing methods.

Picture : MIM parts inserted in zinc die casting

 
3. Gate position

Gate position is determined by the shape of the product and the partitioning of the mold.
Gate position

 

Metal Injection Molding Products

Gears

Gears

Variant holes, Screws

Irregular holes and screws

Thin-walled

Thin-wall parts

Sharp edge

Parts with sharp corners and edges