complexity simplified through metal injection molding

Innovative Metal Working

Process- MIM Compound... Inject… Sinter… Use.

Indo-MIM Confidential

Conventional Method:

Counter hole drill & Reaming

Thread Tapping

Cylindrical tube machined to convert in to a blank

profile

Gear Profile making using Gear Shaper Machine

Slot Cutting

Conventional Method of metal working

Chamfer on the legs & ID


What if we can do this ?? What, If We can do this??


Complexity Simplified through - MIM

Raw Material

Machining

Gear Forming

Slot cutting

Counter hole drilling

Finished Part

MIM

Simplify the complex shape making process to one single operation of

MIM

Thread Tapping


Contents

• What is MIM?

• WHY MIM?

•What is CIM?

• Why INDO-MIM?

• Our Customers

• Case Studies


METAL INJECTION MOLDING MIM is .…


Introduction

• Marriage between Powder Metallurgy and Plastic Injection Molding – (Metal Injection Molding)

• The need for complex shaped parts in large volumes with short lead times triggered the MIM technology

• Defense industry was the mother of MIM. Other industries like Electronics, Consumer, Automotive use MIM extensively today


4 SINTERING

• Inter particular welding

3 DE-BINDING

• Solvent • Thermal

2 MOLDING • Binders melt • Carries powder Into mold

1 COMPOUNDING

• Powders • Binders

Simplicity in complexity

MIM Process


Fine metal powder less than 20µ particle size is blended with

thermoplastic and wax binders in precise amounts to form feedstock

Compounding

Feedstock is the input for molding the part


Molding

Feedstock is injected into a metal mold to form the net shape

Molding machine Molding Tool Green parts


Debinding

Primary binders are removed from the molded part


Sintering

The parts are slowly heated in a protective atmosphere to drive out the remaining binders. Once the binders are evaporated, the part is

heated to high temperature where the void space between the particles is eliminated as the particles fuse together


Challenge is in predicting the shrinkage to achieve final dimensions accurately first time right

Molded part

Sintered part

From Powders to Net shape

Sintering shrinkage

~ 20%

Feedstock

Binder

Metal powder


What happens during sintering?

Scanned Electron Micrographs of MIM parts at various manufacturing stages

Phase 1

Phase 2

Phase 3


WHY MIM ?


Metal Injection molding

High

Investment casting

Prod.Qty

6 10

Complexity

5

4

10 Low Medium

Machining

Die Casting

10

10

3

Press and

Sinter

Low

Medium

High

MIM vs other manufacturing methods - Productivity


Press and

sinter Un

it C

ost

Machining

Casting

MIM

Low Medium High

Complexity

MIM vs other manufacturing methods - Cost


0 250 500 750 1000 1250 1500

P/M

MIM

Ultimate Tensile Strength, MPa

P/M MIM

Material Strength

MIM vs PM

MIM vs other manufacturing methods - Strength


1090

1380

38

1040

1320

38

0

200

400

600

800

1000

1200

1400

1600

YS (MPa) UTS (MPa) Hardess (HRC)

MIM 4605(Fe2Ni0.4C)

En 19A

1090

1380

38

1040

1320

38

0

200

400

600

800

1000

1200

1400

1600

YS (MPa) UTS (MPa) Hardess (HRC)

MIM 4605(Fe2Ni0.4C)

En 19A

Material Strength similar to wrought material


MIM Vs Traditional Metal Forming Process…


Case hardened

steel

•MIM8620

•MIM9310

•MIM4600

Through hardened

steel

• MIM4650

• MIM4340

• MIM4140

• MIM52100

Stainless steel

• SS17-4Ph

• SS304 L

• SS420

• High Temp application

• SS440C

• SS310Nb

• SS310

• Corrosion resistant

• SS316L

• SS310Nb Magnetic Material

• Fe3Si

• SS430

• Fe-49Co-2V

Heavy/Super Alloys

• WHA1

• WHA2

• Inconel

• Nimonic90 Tool Steel • S7, M2, D2

Materials we offer…


MIM is best at…

MIM

Threads

Calligraphy

Knurling Complicated

profiles

Angular holes


MIM can be treated like any other wrought material

MIM

Machining

Grinding

Heat treatment

Surface treatments

Tumbling

Plating, Polishing

Welding

Sizing


What is an ideal MIM part ?

MIM Weight limit <200gms

• Ideal 0.1 to 50gms

Annual Requirement from 50,000 to 20

Mil is possible

Length limit<200mm

• Ideal < 60mm

Wall thickness 0.5mm to 5mm

• If >5mm, coring is essential

Tolerances as per ISO 2768 (M) and

thumb rule of ±0.5% of nominal dimension

All the high melting point alloys are possible.

• (Materials like Brass, Aluminum, Magnesium is not MIM feasible)


MIM fits everywhere

Medical

Power tools Sanitary Aerospace

Computer hardware Electronic connector Automotive Mobile phones

Locks


Ceramic Injection Molding (CIM)

Powder to Finished Parts

Aluminum Oxide (Alumina) 96% pure alumina:

• For parts that require good wear and corrosion resistance, such as in electrically insulating bodies and the vacuum industry

• Maximum temperature of use: 1600° C

Aluminum Oxide (Alumina) 99.8% pure alumina:

• For parts that require good wear and corrosion resistance, such as in Thread guide, Spark plugs Insulators, electrically insulating bodies and the vacuum industry

• Maximum temperature of use: 1600° C

ZTA and Zirconium Oxide :

• For parts that require good wear and Bio compatible such as Medical device and implants

CIM Materials

Medical/ Dental applications

• Orthodontic brackets

• Dental Implants

• Prosthetic replacements

• Abutments

• Endoscopic tools

• Tweezers

Textile Industry

• Wire guides

• Textile Thread Guides

• Twist Stopper

Watches/ Jewelery

• Precision watch gears

• Watchcases

Communication

• Ferrules

• Optical Sleeves

• Soft Magnetic components

Exhaust system Components

• Oxygen Sensor components

CIM Applications

Metallurgy

• Ceramic Casting cores

Automotive Components

• Valve components

• Turbocharger rotors

• Swirl chamber for high power

• turbocharged Diesel Engines

• Radial rotors with integrated ceramic shaft

• Airbag components

• Gear Wheel for fuel pumps

Electrical Components

• Electrical components for automotive exhaust

• Microwave dielectric components

Home appliance and office equipments

• Injector for precolators

• Paper Mill grinding gears

• Inkjet printheads

• Back cover of mobile phones

CIM Applications

Engine Components/ Engineering

• Water Pump seals

• Nozzles, guides, gear wheels, screw threads

• Stators, Precision dispensing nozzles

• Sensor covers and sensor tubes

• Tooth belt wheel

• Bearings

• Seals

• Scissors

• Micro Electrodes for ultrasonic welding

• Drill Bit

CIM Applications

WHY Indo-MIM


Indo-MIM Fast Facts

2011 2012 2010 2011 1997

Start of Joint

venture

Independent

company

Starting of second

plant

Aerospace

division

Medical facility,

Titanium Injection,

Ceramic Injection

molding

Starting of

Investment casting

World’s Largest

MIM company

2006 2001


Our Markets

26% 20% 2% 30% 22%

Industrial Medical Defense Auto Consumer

Manufacturing Facilities

Gowri IC

11000 Sq M

Short to medium run

Engineering

Admin

22000 Sq M facility

Tool room, plating shop

$8 Ml Green field project

High volume

Aerospace

Medical

At Tirupathi, 250 kms from Bangalore

3500 Sq M


Additional 10000 sq.M being added


Type Current Quantity (numbers)

Being added in next six months (numbers)

Molding Machines 95 22

Sintering Furnaces – Batch 14 8

Sintering Furnaces – Continuous 3 1

Milling Machines 17 3

EDM’s (Mitsubishi -11) (Makino -02)

13 2

WEDM’s 4 1

Expansion Plan

Integrated MIM Manufacturing

Design, Engg&

Tooling

Quality system

• ISO 9001:2008

• ISO/TS 16949:2009

• ISO 13485: 2003

• ISO Class 8 Clean Room

•AS 9100 : 2009-01 Rev.C

Feedstock

Injection

Molding

Debinding and

Sintering

Secondary

operations


CASE S t u d i e s


Case study -1

Problem • Conventional machining

– more lead time

• More operations

• High rejections

• Less strength at welded features

• Burrs due to hole forming

• Welding of half circle profile to the cylinder

• Hole forming

Solution • Component made

in MIM

• Only one secondary operation

Results • Cost savings more than

40%

• Less lead time

• Increased customer sales

Product Application : Auto Slack Adjuster

Critical requirement : High wear resistant, less lead time,

increased productivity


Case study -2

Problem

• To make multiple holes of 0.5mm dia.

• Inconsistency in hole dia.

• Longer lead times

• To meet the annual requirement of 200 K

Solution • Component made

in MIM

Results • O.5 mm dia

outlet holes achieved in as sintered condition

• 200 K can be achieved very easily

• 100% consistency in all the dimensions

Product Application : Fuel Injection Nozzle

Critical requirement : Out let holes of 0.5mm dia and corrosion

resistance


Case study -3

Problem

• PM Process+ Machining operations

• Part size is big due to lower material strength

Solution • Redesigned the

part to smaller ,size ,weight and all the features by MIM process at lower cost

• No secondary operations

Results • Near net shape as

sintered

• Less lead time

• High volume

• Increased customer sales

Product Application : Control lever

Critical requirement : Reduce weight, costs and increase strength


MIM integrates different operations…

Earlier method

• Stamping + Bar stock pins + Riveting of pins + Plating

MIM Method

• As-sintered + Plating


Pictorial image of Tool Design

Market Segment Automotive Challenge Indo-MIM solution

Y junction hole cross section

Tool made with 6 slides for all the cross holes.

Engineering Milestones


Market Segment Automotive Challenge Indo-MIM solution

12 slides in the tool and Part weight of 160

grams

Tool made with 12 slides in rotary axis and part successfully made in

MIM

Pictorial image of Tool Design

Engineering Milestones



Our Customers – Automotive


Our Customers – Consumer and Industrial

http://www.swisstechtools.com/default.aspx


Our Customers – Medical components

The word “simplicity” exists because of “complexity” So, don’t think that your design is complex. We are here to make it simple


Indo-MIM Offices

Princeton, New Jersey

Stuttgart, Germany

Shanghai,China

Bangalore, India

Brasilia, Brazil

Taipei, Taiwan

Tokyo, Japan

Sales Offices

Headquarter

Planned office by FY 15

Contacts

MIM & Finishing Operations: #45[P], KIADB Industrial Area, Doddaballapur, Bangalore 561 203 Tel: +91 80 763 0533/ 763 0532 Fax: +91 80 2763 0532 Email: [email protected]

Headquarters & MIM Operations: No 45,(P) KIADB Industrial Area, Hoskote, Bangalore 562 114. Tel: +91 80 2204 8800/2797 1418/2797 1416 Fax: +91 80 2797 1624 Email:[email protected]

USA: 214, Carnegie Center Suite 104, Princeton, New Jersey 08540 Ph: 734-327-9842/734-327-9872/609-651-8238 Fax: 734-327-9873 E-mail : [email protected]

EUROPE: Indian Business Center, Oskar – Lapp Str.2 70565 Stuttgart-Vaihingen, Germany Tel: +49 173 65500242 / +49 173 65500243 Fax: +49 711 65500241 E-mail: [email protected]

IC Operations: Gowri Ventures Pvt.Ltd. Plot # 62B (Part II), APIIC Industrial Park, Gajulamandyam, Renigunta 517 520, AP Tel: 91. 9390845662/63/64 & 65 Email : [email protected]

CHINA : 11F Aurora Plaza, No. 99 Fu Cheng Road Pudong New Area 200120, Shanghai Tel: +86 (0) 21 6058-9206 Fax: +86 (0) 21 6058-9376 E-mail: [email protected]


TAIWAN: 1F, No.436, Anji St., Zuoying Dist. Kaohsiung City 813, Taiwan (R.O.C) Ph: 886-6-2089488 Fax: 886-988664706 E-mail : [email protected]

JAPAN: Kotoku, Kameido 1-16 Tokyo, Japan, 136-8521 Tel: +81 03-3363-2271 Fax: +81-03-3683-6103 E-mail : [email protected]

THANK YOU


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