Patent ID: 8591804

Claim:
A method of metal injection molding on an injection molding machine having a heated barrel with an increasing temperature gradient, the method comprising: providing a metal alloy feedstock including a first component having a first melting point and a second component having a second melting point that is higher than the first melting point, the first component includes a metal alloy comprising about 95 wt % zinc and about 5 wt % aluminum, the first melting point and the second melting point selected to match the temperature gradient of the heated barrel of the injection molding machine; feeding the metal alloy feedstock into the injection molding machine; melting the metal alloy feedstock within the heated barrel of the injection molding machine; and maintaining the percentage of solids to liquids in the metal alloy feedstock of the first component and second component within a processable range of about 5% to about 30%.