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Injection Molding and Powder Metallurgy Comparison

By February 24, 2022 No Comments

Manufacturers across the world are always interested in creating well-performing metal components. They are interested in getting more structural freedom without cost sacrificing. When conventional casting methods do not cut, Manufacturers are getting attracted to other molding methods for driving their items forward. If you are aware of powdered metallurgy, you know that the components are created from metal that is pushed together inside a die and then shaped by a powder metallurgy manufacturer. Metal injection molding is a balancing procedure that utilizes significantly finer metal particles to produce high-density parts with three-dimensional structural flexibility.

Metal Injection Molding and How It Differs?

The metal injection molding method merges two developed technologies, powdered metallurgy and plastic injection molding. It frees every designer from the conventional constraints faced while attempting to shape titanium, copper, nickel-iron, stainless steel, and other metals. Metal injection molding done with the help of a metal injection molding manufacturer has a unique combination of the durability and strength of metal with the injection molding process’s structural flexibility. Metal injection molding and powdered metallurgy use their same base providers, and both procedures allow for the employment of custom compounds; nevertheless, the crucial difference is particle size. Coarser powders utilized in powdered metallurgy are well known, and the way to reach them is not expensive. Metal injection molding powders are much minor, so the energy and process for manufacturing them- in that magnitude range- are more costly for producing. The powdered metal’s cost is a crucial driver when comparing powdered metallurgy and metal injection molding materials. Metal injection molding powders are usually more costly than powdered metallurgy powders as they are finer (plus hundred microns vs minus twenty microns). Nevertheless, due to the finer material metal injection molding produces less porosity.

Design Freedom

Engineering professionals often confuse traditional powdered metallurgy and metal injection molding, given that both begin with powdered metal. Powdered metallurgy depends on a high-pressure uniaxial compression. Powdered metallurgy suits simple shapes more easily ejected from the die cavity. Here metal injection molding differs. There are very few – if any-geometrical limitations permitting for three-dimensional structural freedom with metal injection molding. Other design enhancements for metal injection molding parts are below

  • Component consolidation
  • Uniform thickness of the wall
  • Mass and coring reduction
  • Slots and holes
  • Undercuts
  • Threads
  • Logos, letter and knurling

Physical Attributes

Whereas the powdered metallurgy and metal injection molding procedures might seem like the main differences between them can be witnessed in the finished component’s final attributes- significantly the final density. Whenever you employ the powdered metallurgy process, the conflict between the tooling and powder makes the eventually produced part non-uniform, whereas metal injection molding components have uniformity in every direction. Additionally, shaping for metal injection molding is done at much greater temperatures than powdered metallurgy (two thousand three hundred and fifty to two thousand five hundred Fahrenheit vs one thousand eight hundred to two thousand Fahrenheit). The bigger powdered metallurgy metal powders, combined with lower shaping temperatures, cause the final powdered metallurgy part to have lesser physical attributes, making metal injection molding parts around two times more powerful with significantly better fatigue strength and toughness.

Where Does Metallic Injection Molding Fit?

Where people add cost for costly tooling and feedstock, you realize savings as far as high-complexity, high-density parts are concerned that cannot be manufactured by every other production method. Powdered metallurgy might be a cost-efficient alternate for simple components, but metallic injection molding can manufacture component geometrics that destroys secondary operations which can help cut down costs significantly. Several people find massive savings when they combine a couple or more subparts into a single metallic injection molding part.

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