Application and Advantages of Metal Injection Molding (MIM) Technology in the Production of High-Density Thin Sheets

The manufacturing process of dense thin sheets using Metal Injection Molding (MIM) technology presents numerous technical challenges. Through continuous research and technological innovation, MIMO has successfully overcome these challenges and delivered high-quality products that satisfy its customers.

1. Thickness Control and Uniformity of Thin Sheets

Technical Challenge:
In the manufacturing of dense thin sheets, controlling the thickness and uniformity of the sheet is a key challenge. The thinness of the sheet demands extreme precision in material flow, injection pressure, and mold design. Without proper control, issues such as uneven thickness or surface defects could arise, negatively impacting the sheet's mechanical properties and appearance.

Breakthroughs and Approaches:

• Mold Design Optimization: MIMO optimized material flow paths within the mold through precision mold design and flow analysis, ensuring uniformity during the sheet forming process.

• Precision Injection Technology: High-precision injection molding equipment combined with an intelligent control system accurately manages injection pressure and speed, ensuring consistent thickness and dimensions across all sheets.

2. Deformation Control During Debinding and Sintering

Technical Challenge:
During the debinding and sintering process, thin sheets are prone to deformation or warping due to their thinness, which can affect flatness and fail to meet mechanical performance standards.

Breakthroughs and Approaches:

• Phased Debinding Process: MIMO developed a phased debinding process to gradually remove the binder, reducing the risk of deformation caused by uneven heating.

• Precision Sintering Control: The introduction of a high-precision sintering control system enables precise adjustment of sintering temperature and time. Special sintering support devices are used to minimize deformation and ensure flatness during the sintering process.

3. Precise Control of Shrinkage Rate

Technical Challenge:
Thin MIM sheets experience shrinkage during the sintering process, and due to the special shape and size requirements of the sheets, precise control of the shrinkage rate poses a significant challenge.

Breakthroughs and Approaches:

• Shrinkage Rate Data Model: MIMO has developed shrinkage rate data models for various materials through extensive experimentation, accurately predicting and compensating for size variations during the forming process.

• Mold Design Compensation: Adjustments based on the shrinkage rate model are made during the mold design phase to ensure dimensional accuracy of the finished product, successfully reducing issues with size discrepancies.

4. Surface Quality and Mechanical Performance

Technical Challenge:
Dense thin sheets require high surface quality and mechanical performance. Any minor surface defect or material inconsistency could affect the final performance of the product.

Breakthroughs and Approaches:

• Surface Treatment Technology: MIMO implemented precision surface treatment processes, such as polishing and chemical treatment, to improve surface quality and eliminate microscopic cracks or other defects.

• Material Optimization: By adjusting powder composition and injection parameters, MIMO enhanced the density and uniformity of the sheets, improving their mechanical properties such as strength and wear resistance.

  
  

5. Consistency in Mass Production

Technical Challenge:
Ensuring product quality consistency in mass production is crucial, especially in thin sheet manufacturing, where even minor deviations could affect the pass rate of the entire batch.

Breakthroughs and Approaches:

• Comprehensive Quality Control: MIMO established a thorough quality control system, from raw material selection to production monitoring and final product inspection, ensuring that every sheet meets strict quality standards.

• Automated Production Line: The introduction of an automated production line minimizes human error, enhancing production stability and product consistency.

  
  

Conclusion
Through multiple technological breakthroughs in the manufacturing of dense thin sheets via Metal Injection Molding, MIMO has successfully addressed various challenges in the production process, significantly improving product performance and earning high customer satisfaction. Looking ahead, MIMO will continue to deepen its research and application in the MIM technology field, ensuring it remains at the forefront of market competition.