Metal Injection Molding.

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Alban Taylor
5 years ago
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1 Metal Injection Molding

in terms of design, manufacturing, sourcing and marketing to a

electronics, automotive, IT industry, hand power tools,

Established over ten years ago, Easea has been supplying

steel, heavy alloy and cemented carbide alloy.

manufacturing facilities and rich production experience, we are

millions of pieces at a competitive price.

2 Company profile Easea International Ltd. specializes in providing Metal Injection Molding (MIM) solutions in terms of design, manufacturing, sourcing and marketing to a wide variety of industries, such as defense industry, electronics, automotive, IT industry, hand power tools, consumer, and medical instruments, etc. Established over ten years ago, Easea has been supplying millions of parts every year for the military and commercial customers. Our major product ranges are made from Fe-Ni alloy, stainless steel, heavy alloy and cemented carbide alloy. With our experienced technical staff, state-of-theart manufacturing facilities and rich production experience, we are capable of supplying your orders whether in thousands or millions of pieces at a competitive price. Using MIM technology, we provide a simple solution for your complex parts. Our manufacturing facilities are ISO 9001:2000 certified. We are sincerely looking forward to establishing long-term business relationship with customers from all over the world.

State-of-the-art manufacturing facilities.

3 Company profile Over ten years MIM production know-how. Approved supplier for firearms manufacturers. ISO 9001:2000 certified. State-of-the-art manufacturing facilities. Continuous type furnace, suitable for high volume production. Batch type furnace suitable for pilot series or low volume applications.

4 Company profile Manufacturing and testing/measuring equipment.

parts, sewing machine fittings, printing machine

5 Company profile Product ranges: hand/power tools parts, firearms parts, automotive parts, mechanical/electronic parts, sewing machine fittings, printing machine components, stainless steel medical instrument components, watch and lock components, etc. Customers: Black & Decker, Bosch, SATA, firearms manufacturers, contract manufacturers, subcontractors, etc.

MIM technology Metal Injection Molding(MIM) is an advanced technology. It offers myriad tangible advantages over other manufacturing processes.

solution. Using extremely fine metal powders, MIM technology produces parts in high-density and near net-shape with the properties approaching that of wrought material.

6 MIM technology Metal Injection Molding(MIM) is an advanced technology. It offers myriad tangible advantages over other manufacturing processes. In fact, where small part size, part complexity, and high volume are primary factors, this sophisticated, time-saving, and costeffective technology is often the optimal solution. Using extremely fine metal powders, MIM technology produces parts in high-density and near net-shape with the properties approaching that of wrought material. Ferro-nickel alloy, stainless steel, carbide alloy, and other nonferrous alloys such as titanium, are common materials for MIM. Mounting support: Ferrite alloy; 0.05g; 1 million pieces per year.

MIM technology More significant, the MIM process allows engineers more latitude when designing a component, no longer constrained by the parameters of cost, size, or shape.

7 MIM technology More significant, the MIM process allows engineers more latitude when designing a component, no longer constrained by the parameters of cost, size, or shape. The value of removing these restrictions from the engineer's thought process cannot be overstated. MIM will find more application opportunities from the freedom of designing.

8 MIM technology MIM Process Binder Mixing Molding Debinding Metal powder Mold making Mold Making Molds similar to those used in conventional plastic injection molding are designed and fabricated. CAD/CAM technology is used to enhance the design and fabrication process. Mixing Fine metal powders, thermoplastic binders and other proprietary materials are mixed to form a homogeneous feedstock. Molding Conventional injection molding machines are used to create green parts. These parts are typically 15-20% larger than the finished product. Debinding Green parts are exposed to heat, solvent or a combination of both to remove most of the binder material. The de-bound are called brown parts. Sintering Post processing Sintering Brown parts are sintered in vacuum-type furnaces. The intense heat shrinks the parts 17-22% to almost complete density, however the shrinkage has already been taken into consideration when the molds are designed. The parts are then complete. Also, secondary machining or surface treatment is available.

9 MIM technology MIM Advantages MIM applications are ideally suited for components that are relatively complex, very small, and will be produced in large quantities, at the same time requiring high strength, high performance and cost efficiency. Comparison between MIM & Other Processes Process Complexity Min.Wall Thickness Material Selection Density Finish Tolerance Capability High Volume Capability Complex Part Cost Simple Part Cost MIM Very High 0.5mm Many 95~99% Ra 4μm Good Very Good Very Low Medium P/M Low 1mm Many <95% Medium Good Very Good High Low Die Casting High 0.8mm Very Few 100% Medium Medium Medium Low Very Low Investment Casting Medium 2mm Medium 100% Ra 5μm Poor Medium Medium Medium Machining High 0.5mm Quite Many 100% Very Good Very Good Poor Very High Very High

10 MIM technology MIM Advantages Comparison between MIM & Other Processes

11 MIM technology MIM Part Selection Criteria Size: From 0.1 grams to over 150 grams in weight. A volume of, or less than, a golf ball or deck of playing cards. Complexity: Typically if a part has more than 25 measurable dimensions it will make a good candidate for MIM. Quantity: The quantity of parts plays a major role in the cost effectiveness of MIM. 10,000 pieces per year is as a minimum in most cases. Tolerances: ±0.03 ~ ±0.05mm per cm. These are sound guidelines, yet not the absolute criteria. There are some fairly large parts or parts in low quantities produced by MIM, simply because they are just too costly to produce using traditional methods.

12 MIM technology MIM Materials Properties of Typical MIM Materials Material Group Alloy Name UTS MPa YS (0.2%) MPa Elong.% Hardness Density g/cm3 Low Alloy Steels 8% Ni-Steel HRB 7.6 MIM 4605 as sintered HRB 7.5 MIM 4605 heat treated HRC 7.5 Austenitic AISI 316L HRB 7.7 Stainless Steels AISI 304L 7.7 Ferritic SS AISI HRB 7.5 Stainless Steel Martensitic AISI HRC 7.3 Stainless Steel AISI 420 (Premium) HRC 7.6 AISI 440C (Premium) HRC 7.5 Precipitation Hardening 17-4 as Sintered HRC 7.6 Stainless Steel 17-4 PH H HRC 7.6 Duplex Structure ASTM A276 (2205) HRB 7.5 Stainless Steel Soft Magnetic Fe-Si HRB 7.5 Materials Alloy HRB 7.7 Copper Based Cu 100% 8.3 Titanium Ti-6AI-4V (ANNEALED) TI-6AI-4V (AGED) High Speed Steel M HRC 7.9 Tungsten Heavy Alloy WHA 320Hv1 17.8

13 MIM technology MIM Materials MIM Material Chemstries Material Group Alloy name C wt% Cr wt% Ni wt% Mo wt% Cu wt% Si wt% Fe wt% Other wt% Low Alloy 8% Ni-Steel 0.6 max* max 0.5 max Steels MIM 46XX* 0.6 max* max 0.5 max Austenitic AISI 316L 0.03 max max P O.045 max,s 0.03 max Stainless Steels AISI 304L 0.03 max max P O.045 max,s 0.03 max Ferritic AISI max max P 0.04 max,s 0.03 max Stainless Steel Martensitic AISI min max P 0.04 max,s 0.03 max Stainless Steel AISI 440C max P 0.04 max,s 0.03 max Precipitation 17-4 PH 0.07 max max P 0.04 max,s 0.03 max Hardening Stainless Steel Duplex Structure ASTM A276 (2205) 0.03 max max P 0.03 max,s 0.02 max Stainless Steel Soft Magnetic FeSi 0.1 max 2-3 Materials Alloy max 50 nom Copper Based Cu-100% 99 nom Titanium Ti-6AI-4V 6% AI,4% V, Balance Ti High Speed steel M max 6% W, 2% V Tungsten Heavy alloys WHA W * Carbon levels are variable with application

14 MIM technology MIM Applications Automotive: airbag firing pins, power window system, safety belts, jacking systems of auto doors, small gears, auto AC systems, turbo fans, racks of braking systems, and sensors of fuel systems. Firearms: small arms parts, armour-piercing bullet core, fuzes. IT industry: typewriters, hard disc drive parts, magnetic cores, axle pins, and porcelain plugs of fiber optical communications. Tools: drill bits, clamps, nozzles, thread milling cutters, pneumatic tools, power tools and fishing gears. Medical instrument: orthodontics brackets, laparoscopic parts like graspers, dissectors, tweezers and instrument handles. Electronics: Mini motors, connecters, mobile phone hinges, keys and sensors Other applications: watchcases, watch chains, electric toothbrushes, scissors, golf heads, jewelry pendant and links, cutting tools and locks.