Production of light wave conncectors, hermetic housings, heat sinks etc. by the MIM process

Abstract

By metal powder injection moulding (MIM) and ceramic powder injection moulding (CIM) near net shape components are produced of complex geometry with good surface finish and close tolerances. Through the use of much finer powders than commonly used in conventional sintering, parts are obtained with higher densities and enhanced mechanical properties with very uniform microstructure. The MIM technology aims at the production of complex, small components, difficult to produce satisfactorily and economically by known methods and from materials difficult to machine or otherwise to transform. Ideal component candidates are not only in new developments but also in existing products, by the combination of two or more parts into one single one and by avoiding expensive post machining and handling operations. Apart from fibreoptic components, hermetic housings, heat sinks etc, typical components are complicated small gears, parts for control and locking mechanisms, automotive fuel injection parts, automotive valve drain parts, airbag sensor parts, magnetic parts, computer disk drive parts etc. Materials range from NiFe, stainless steels, NiCo alloys, Ti alloys, WCu and MoCu to Alumina, translucent Alumina, Zirconia, Silicon Nitrides etc. Typical densities in the sintered form are from 93 to 100%. Surface finish 0.8 to 1.5 μ. Tolerances ± 0.3 to ± 0.2 % of nominal dimensions. Max weight approx 50 gr. CPK values > 1.45 on critical dimensions. MIM is a mass production process and offers best cost efficiency at high production quantities.