MIM offers significant cost savings for new designs that can be tailored to take advantage of the benefits of the process. Directly converting simple stamping, forging, die casting, or conventional powder metal parts to MIM generally does not offer a cost reduction. However, when two or more of these parts can be incorporated into a single MIM design, total overall component count and cost can be greatly reduced, notes Ryan. In addition, these components may also have improved mechanical properties, surface finishes, and corrosion resistance.
Total savings are a function of shape complexity, production volumes, part size and material used.
Part sizes can be up to 150 grams, although most parts produced are fewer than 30 grams. MIM molds are similar to those used for plastic injection molding, and the cost is usually justified when production quantities are higher. As in tooling for plastic injection molding, molds are often designed with multiple cavities to reduce processing costs. Phillips' in-house tooling capabilities can be employed to ensure a seamless line of communication during the tooling phase of the program. Although leadtimes vary by program, typical MIM leadtimes are from 10 weeks to 16 weeks for delivery of approved samples.