Epma Introduction To PM Mim

european powder
metallurgy association
Promoting Powder Metallurgy Technology
I N T RO D U C T I O N TO
METAL INJECTION
MOULDING
TECHNOLOGY
A Manufacturing Process for Precision
Engineering Components
AN EPMA SECTORAL GROUP

© Fraunhofer IFAM
© Parmaco
Process | Properties & Testing | MIM Design

Technical Guidelines | Case Studies
www.epma.com/mim
4th Edition
european powder
Representing the European PM industry
European Metal Injection Moulding Group

What is the European Metal Injection Moulding Group?
The European Metal Injection Moulding Group (EuroMIM) was formed out of the successful three year
MIM Thematic Network (MIMNet) which finished in October 2000. EuroMIM had its inaugural meeting
in January 2001.
The EuroMIM represents the entire MIM sector supply chain from end users, through to component
makers and raw materials suppliers. The main objectives are:
• Develop the potential and capabilities of MIM.
• To promote MIM to end users in particular to promote EuroMIM members specialties.
• Provide a united European voice to the outside world.
By joining the EuroMIM group, a company gains access to the leading PM MIM network in Europe, from
the full range of EPMA activities in areas such as REACH legislation, Summer Schools and publications, to
name but a few.
You will need to be an EPMA member to gain full access to the all of the groups benefits including
invitation only meetings.
More information about EuroMIM can be found at www.epma.com/mim
EPMA Membership Benefits

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Metal Injection Moulding
CONTENTS
Introduction to Metal Injection Moulding (MIM)

MIM has over the past decades established itself as a competitive manufacturing process for small precision components
which would be costly to produce by alternative methods. It is capable of producing in both large and small volumes
complex shapes from almost all types of materials including metals, ceramics, intermetallic compounds, and composites.
Components made by MIM technology are finding applications in industry sectors such as automotive, chemical, aerospace,
business equipment, computer hardware, bio-medical and armaments.
Page
1. INTRODUCTION 4
2. RAW MATERIALS USED IN MIM 5
2.1 Metal Powders 5
2.2 Characterisation of MIM Powders 6
2.3 Binders 7

2.4 Mixing 7
2.5 Characterisation of MIM Feedstock 7
3. THE MIM PROCESS 9
3.1 Injection Moulding 9
3.2 Debinding 10
3.3 Sintering 10
4. PROPERTIES OF MIM PRODUCTS 12
4.1 Density and residual porosity 12
4.2 Mechanical Properties 12
4.3 Fatigue Strength 14
4.4 Heat Treatment 15
4.5 Corrosion Resistance 15
5. MIM DESIGN GUIDELINES 16
5.1 Part Design 16
5.2 Mould Design 18
5.3 Moulding Simulation 19
5.4 Dimensional Accuracy of MIM Parts 20
5.5 Comparison of MIM with Competing Processes 21
6. INTERNATIONAL STANDARDS FOR MIM 22
6.1 Objective 22
6.2 MIM material designation 22
6.3 Standards on mechanical properties 23
6.4 Standards for non-ferrous MIM materials 23
6.5 Standards for testing MIM parts 23
6.6 Further standards relevant for MIM 23
7. RECENT DEVELOPMENTS IN THE MIM PROCESS 24
7.1 Two Component MIM 24
7.2 Binder Jet 3D-Printing for Prototyping and Small Scale MIM Production 24
8. SUMMARY 25
9. CASE STUDIES 28
Copyright © European Powder Metallurgy Association 2013, 4th Edition 2017, updating 3rd Edition of 2016,
reprint 2017. 4th Edition 2017, update 4th Edition 2018 (web only), 4th Edition 2018 (reprint),
update 4th Edition 2018 (web only), 4th Edition 2019 (reprint)
3
1 INTRODUCTION
Powder Metallurgy
Metal injection moulding (MIM) is a development of
the traditional powder metallurgy (PM) process and is
rightly regarded as a branch of that technology. The
standard PM process is to compact a lubricated
powder mixture in a rigid die by uniaxial pressure,
eject the compact from the die and sinter it.
Quite complicated shapes are regularly being produced
by the million, but there is one significant limitation
regarding shape capabilities. After compaction in the
die the part must be ejected, i.e. pushed out of the die
cavity, therefore parts with undercuts or projections at
right angles to the pressing direction cannot be made

directly. This limitation can be substantially overcome
by use of the metal injection moulding process. Fig 1.1: Collection of Metal Injection Moulded Parts

The use of injection moulding for the production of intricate
parts in a range of plastic materials has been employed for
many years and most of us come into contact with them in
some form or other every day. One important feature of such
parts is that they are relatively cheap. For many engineering
applications, however, these thermo-plastic materials cannot
be used because of their inadequate mechanical properties.
They are relatively soft, have limited strength and cannot
tolerate elevated temperatures.
Some improvement in mechanical performance is possible
through the use of solid fillers – ceramic or metal powders –
but the real breakthrough occurred when it was found possible
to incorporate a very high volume fraction of metal powder in
a mix so that, instead of a filled plastic part, a plastic-bonded
metal or ceramic part is produced. Careful removal of the
plastic binder leaves a skeleton of metal or ceramic which,
although fragile, can be handled safely and sintered in much the
same way as traditional die compacted parts. After sintering
densities of 95% or more are achievable and consequently the
resultant mechanical properties are generally superior or
equivalent to those of traditional PM parts.
A schematic showing the basic steps of the metal injection Fig 1.2: The Metal Injection Moulding Process (Courtesy IFAM)
moulding (MIM) process is shown in Fig. 1.2
4
2. RAW MATERIALS USED IN MIM
In the traditional Press and Sinter PM process the parts produced after sintering have dimensions that are very close to the
original ‘green’ compact, consequently it is relatively straightforward to achieve narrow dimensional tolerances. With MIM
however the situation is quite different. The ‘green’ compacts produced after the injection moulding step contains a high
volume percentage of binder, up to 50%, such that when the binder is removed during sintering significant shrinkage occurs.
It is therefore critical that the sintering process is accurately controlled in order to ensure that a uniform and predictable
level of shrinkage occurs. Compared to the conventional PM process, MIM has the advantage that the density of the metal in
the green compact is uniform, provided that the feedstock has been manufactured correctly. In MIM shrinkage, though large,
is also uniform. These two combined factors eliminate the occurrence of distortion that is observed in die-compacted parts
due to variations in density.
The rheological properties of the powder/binder mix, or feedstock as it is called, are of major importance in MIM. The
feedstock viscosity during injection must ensure that the mixture flows smoothly through the die and into the mould whilst
avoiding segregation. At the same time the viscosity must also be constant across the range of moulding temperatures used
and also the mixture must become rigid on cooling so that the green compacts can be handled without being damaged.
These requirements dictate the type of binders that can be used and to some extent the particle size distribution of the

metal powders. Let us look first at the powders.
2.1 Metal Powders

Almost any metal that can be produced in a suitable powder form can be processed by MIM.
The main exceptions are aluminium and magnesium; the adherent oxide film present on the
powder surface of these metals inhibits sintering. The list of metals that have been used in
metal injection moulding is constantly expanding and includes:
Stainless steels Refractory metals and hardmetals (cemented carbides).
Low alloy steels Copper alloys
a) Carbonyl Iron Powder Tool Steels and High Speed Titanium,

(Courtesy BASF) Nickel based Superalloys Intermetallics
Cobalt alloys Magnetic alloys
The net shape capabilities of MIM can be leveraged to best effect for high value alloys as you can avoid the generation of
those process scraps that are associated with machining.
The term 'suitable powder form' deserves further explanation as, in reality, there are some conflicting requirements to
consider. Particle shape is important for a number of reasons. It is advantageous to incorporate as high a proportion of
metal as possible, which means that powders with a high packing density are desirable. Consequently spherical or near
spherical powders would appear to be preferable, however this can increase the risk of part distortion during the debinding
process (unlike in a die pressed compact there is no metallurgical bonding between the particles in a MIM green compact).
Average particle size and particle size distribution are also important. Another factor to consider is that fine powders will
sinter more readily than coarser powders and can potentially achieve higher density levels. The following table compares the
different powder production techniques used for manufacturing MIM powders today.
b) Gas atomized 17-4 PH powder (Courtesy IFAM) c) Water atomized 17-4 PH Powder (Courtesy IFAM)
Fig. 2.1: Iron and steel powders used in MIM
5
Comparison of Small Particle Production Techniques
Technique Size [µm] Shape Materials

Gas Atomisation 5 to 40 Spherical Metals, Alloys
Water Atomisation 6 to 40 Rounded, Ligamental Metal, Alloys
Carbonyl 0.2 to 10 Rounded to Spiky Metals
From ‘Injection Moulding of Metals and Ceramics’ by RM German & A Bose, published by MPIF, Princeton, USA
The Ideal MIM Powder Characteristics are:

• Tailored particle size distribution, for high packing density and low cost (particle size distribution to incorporate lower
cost large particles and higher cost small particles)
• No agglomeration
• Predominantly spherical (or equiaxed) particle shape
• Sufficient interparticle friction to avoid distortion after binder removal

• Small mean particle size for rapid sintering, typically below 20 microns
• Dense particles free of internal voids
• Minimized explosion and toxic hazards
• Clean particle surface for predictable interaction with the binder
In reality the choice is restricted to what is available but growing demand has stimulated a major effort by powder
manufacturers to produce powders that meet the special requirements of MIM.
2.2 Characterisation of MIM Powders

The test methods commonly applied in powder metallurgy to characterise powders used in traditional Powder Metallurgy,
such as sieve analysis, flow rate or compressibility are not applicable to MIM powders as their particle size is significantly
smaller than that of powders used in die compaction. The test method recommended for characterizing the particle size
distribution of MIM powders is laser diffractometry/scattering (Fig. 2.2). The technique has a large dynamic range (between
1 and 1000µm) which adequately covers the size range of interest in MIM technology. A typical plot of the volumetric
particle size distribution of a gas atomized 316L powder for the manufacture of MIM parts exhibiting the accumulative and
differential curve is shown in Fig. 2.3. The mean particle size D(50) and the 10% and 90% values D(10) and D(90) are given
as the intersections of the accumulative curve with the respective percentages. Other physical properties can also be
measured to characterise, these include Apparent Density (EN ISO 3923), Tap Density (EN ISO 3953) and True Density.
Fig. 2.2: Schematic of laser diffractometry
Fig. 2.3: Typical particle size distribution of a MIM

powder (gas atomized 316L)
6
2.3 Binders
Selection of the optimum binder is critical to the successful production of injection moulded components. To some extent
the exact compositions and procedures are still proprietary secrets, however, for the most part binders are mixtures of
organic compounds, the main ingredients being natural waxes or synthetic polymers. Other substances may be added to
modify the properties. The table below shows the main binder systems in use today for MIM.
Binder Main Ingredients Polymer Backbone Additives

Paraffin / Microcrystalline /
Carnauba / Beeswax / PE, PP, PS, PA Stearic / Oleic acid and
Thermoplastic Binders Vegetable / Peanut oil / PE-VA, PE-A, PP-A, esters thereof, phthalic acid
Acetanilide / Antipyrine / PMBA-E-VA esters
Naphthalene / PEG
Polyacetal Binder Polyoxymethylene Proprietary
Gelatine Binders Water Methyl cellulose / Agar Glycerine / Boric acid

Mixing is carried out at an elevated temperature such that the binder is in a liquid state; in this condition it must 'wet' all the
powder particles producing a homogeneous mix without creating any clusters of particles. Surfactants are frequently added
to the binder formulation to promote the wetting process. Another requirement is that there must be no chemical reaction
between the binder and the metal, additionally the binder must not deteriorate during the process. Finally, for economic
reasons and to maximise material utilisation, it must be possible to re-use any sprues (runners) and rejected green parts in
the initial granulation step. A further factor of considerable importance is the ease with which the binder can be removed
from the moulded part. This part of the process can be time consuming and therefore represents a major element of the
cost equation.
2.4 Mixing
Tumbler mixers (such as double cone mixers) are widely used for the dry blending or mixing of powders, are of little use for
processing MIM feedstock. In order to ensure that a homogeneous feedstock is produced a shearing action must takes place.
Several different types are available such as Z blade and planetary mixers. When a large amount of work is needed to
achieve the required feedstock homogeneity twin-screw extruders can be used for the final feedstock preparation. A key
requirement is to ensure that the whole of the surface of each particle is coated with binder.
Sometimes the powder is pre-processed in order to facilitate and intensify the contact between particle surface and binder.
As indicated earlier the least possible amount of binder should be used, however the appropriate volume fraction of powder
depends on the powder characteristics. In industrial practice, the volume fraction of powder varies from about 0.5 to 0.7. It
is usual to convert the powder-binder mix, the so-called feedstock, into solid pellets by a granulation process. These
feedstock pellets can be stored and fed into the moulding machine as required.
2.5 Characterisation of MIM Feedstock

Many MIM parts manufacturers buy ready-to-use feedstock
from specialized suppliers. A consistent feedstock quality must
be maintained in order to ensure the quality of the end
product, both in terms of material properties and dimensional
accuracy. Test methods for feedstock characterization should
be agreed between the supplier and the parts manufacturer.
The test methods proposed here have been agreed by the

European MIM industry and are commonly used because of
their simplicity and low cost. They should be preferred
wherever possible. They do not, however, provide a
comprehensive characterisation of the feedstock, but rather a
set of characteristic values that allow the comparison of
different batches of feedstock of the same composition. As
feedstock characterisation is still a relatively young field of
research, new and better test methods may be developed in
the future.
Fig. 2.4: Gas Atomizer, Courtesy of Sandvik Osprey

7
Shrinkage
The shrinkage from the dimensions of the ‘green’ compact to the final dimensions of the MIM component can be regarded
as a property of the feedstock. A draft standard has been proposed for the determination of the shrinkage. Fig. 2.5 shows a
test sample for the determination of the shrinkage of which two diameters are measured perpendicular to each other.
Fig. 2.5: Sample for shrinkage measurement, Courtesy of BASF

Feedstock Rheology
The feedstock viscosity is a very important property in MIM Technology as it determines how well the material can be
transported and injected into the die cavity. When considering flow behaviour one should bear in mind that the term
viscosity can have different meanings depending on the actual conditions of testing.
In terms of flow through a channel or orifice, as simulated in capillary rheometer techniques, low viscosity is associated with
easy flow of the feedstock, ideally this flow would reflect the inherent properties of the feedstock. This is the case if the flow
is laminar as is the case for homogeneous feedstock that does not exhibit wall-slip behaviour. Capillary rheometry is,
therefore, a useful tool for assessing the effect of a wide range variation of the (apparent) shear rate on the feedstock
(apparent) viscosity.
Another particularly important factor to establish when developing a feedstock formulation is the so-called critical loading.
This is the limit of the powder content above which the relative viscosity of the feedstock increases significantly. The critical
loading can be determined by correlating measured viscosity as a function of powder loading at a fixed shear rate. In
polymer science there are various other techniques employed to study rheological behaviour, e.g. controlled stress and
controlled strain rheometers. However, their applicability to MIM feedstock testing is yet to be validated. It should be noted
that these more sophisticated methods can provide a deeper insight regarding how well the powder and binder are
dispersed in the feedstock.
In a commercial context MIM manufacturers must be able to specify the required material properties when sourcing
feedstock. This requires a reliable, standardised measure of feedstock performance for quality assurance purposes. The Melt
Flow Index (MFI) test, i.e. melt mass-flow rate (MFR) or melt volume-flow rate (MVR) testing of thermoplastics, as described
in ISO 1133, can be used. This characteristic is derived by means of passing a defined amount of feedstock through a channel
during a fixed period of time. MVR is measured in cm3/10 min, MFR in g/10 min. An automatic distance-time-measurement
can be monitored (procedure, type B). The test temperature and load applied depend on the type of binder being tested. For
MIM applications, reported MFI values should be accompanied by information on the load or weight that is used, the
temperature and test procedure.
8
3.THE MIM PROCESS
The MIM process is a chain process which consists of moulding, debinding and sintering. Subsequent processes can include
machining, hardening, deburring or surface treatment. Each of these processes has an influence on the final properties and
some properties which are influenced by any of the processes can only be identified in the finished part.

Fig. 3.1: The Metal Injection
Moulding Process
3.1 Injection Moulding

The first step is injection moulding. Injection Moulding of MIM feedstocks
works much in the same way as injection moulding of plastics. The same
moulding machines and similar tool designs are used, too. However, since
MIM feedstocks are more abrasive than plastics and since they are usually
injected at higher pressures, the components which come in contact with
the feedstock are made of more wear resistant materials. Today many
injection moulding machine suppliers offer machines especially equipped for
MIM. At this point the functioning of moulding machines will not be
explained. There is plenty of literature that does that for plastics and the
process is basically the same.
Fig. 3.2: Moulding machine (Courtesy Arburg)
9
The injection moulding process itself, however, is more complex and more difficult to monitor because, unlike plastic
injection moulding, the injection moulded MIM components are not yet in their final state and therefore not all the final
properties can be monitored during the moulding stage. The moulding process is only the shaping process whereas other
properties like strength and dimensions only evolve during the subsequent steps of the process chain.
Commonly the moulding process is largely influenced by the mould design and the part design. Both have a huge influence
on distortion, flow lines, junction lines, powder and binder separation and final dimensions. There are many different binder
systems on the market. Not all the binder systems have the same moulding properties and they also influence the
subsequent processes in different ways. There are binder systems which are favourable for the green strength of the parts
but can have some deficiencies concerning flowability. Others enhance optimal flow but require very accurate moulds
because they otherwise lead to burr formation. Again others are less economical because they require slower debinding.
There is no number one binder system. For a MIM producer it is important to know the characteristics of his binder system
and to understand and counteract its deficiencies in the best and most consistent way possible.
3.2 Debinding
Debinding is the binder removal process. It is the preparation step for sintering and it is needed in MIM to remove the
binder material. After the components have a porous structure since the binder has been removed and are still the same
size as they were after moulding. The time required for debinding depends on the thickness of the parts and the debinding
method applied.
There are several methods for binder removal:
• Solvent debinding uses a solvent to remove the soluble ingredients of the binder. This process works at low
temperatures and is therefore easy on the parts
• In thermal debinding the parts are exposed to temperatures where the polymer binder is evaporated and extracted by
either flowing inert or reducing gas through the furnace or applying a vacuum to the process chamber
• The catalytic decomposition of POM feedstock using gaseous nitric acid or oxalic acid is a widely used debinding
method. It reduces the time needed for binder removal
After the debinding stage, depending on the binder used and the debinding method that is applied, the parts tend to be fairly
fragile and sometimes difficult to handle. It is in the debinding cycle where parts can warp, blister or crack if the process is
not applied properly.
3.3. Sintering
The subsequent sintering process lets the parts shrink to their final size. Depending on the initial binder volume content the
linear shrinkage is between 12 and 20% (mostly 15-18%).
Sintering is a thermal diffusion process where the immense surface area of the powder compacts is transformed into solid
material with a high density. The push for this transformation is based on thermodynamics. The surface energy per volume of
fine particles is much higher than that of coarse particles and therefore strongly promotes the diffusion of atoms. During
sintering the level of surface energy is greatly reduced. Since, opposed to press and sinter, the moulding process works with
very fine powder feedstocks the sintering process of MIM components can push the final density much higher than the
sintering process of press and sinter components. In press and sinter only relatively coarse powders can be used due to the
different shaping method. The density of MIM components is usually above 96% of the theoretical density of the alloy applied.
Sintering can be performed in high temperature furnaces applying process gas or vacuum. The top temperature of the
sintering process is just below the melting temperature. The time-temperature-atmosphere scheme of the process is
important for its result. Usually MIM steel components are sintered between 1200°C and 1400°C depending on their
chemical composition.
Since the parts shrink during sintering the friction between the shrinking
component surface and the underlying ceramic material used for the positioning
of the components can be of importance and can especially influence the final
dimensions of heavy parts. Another fact is that the mechanical strength of MIM
parts at or near the sintering temperature is very low. Therefore slumping due
to gravity can lead to dimensional issues especially when the parts are made of
alloys which undergo liquid phase sintering.
Fig. 3.3: Positioning of the parts is an

important issue during sintering. The parts
must be able to shrink freely with as little
resistance as possible and the action of
gravitational forces must be minimized by
support structures.
10
Both debinding and sintering can be done in a discontinuous fashion or in continuous processes. Discontinuous processes
which take place in individual pieces of process equipment for each process step have the advantage that they are more
flexible and the process routes can be designed for each individual type of product. Continuous process equipment for
debinding and sintering is more economical as long as the processed volumes are large and when there are not many
debinding and sintering program changes from product to product. By and large, high volumes of large parts are usually
processed continuously whereas smaller volumes and small parts are better suited for discontinuous processing.

Fig. 3.4: Continuous debinding and sintering furnace Fig. 3.5: Batch furnace for debinding and sintering
(Courtesy Cremer) (Courtesy Elnik)
Overall, the MIM process with its many sub-processes has hundreds of parameters which need to be controlled. This starts
at the qualification of the feedstock which implies that also the individual ingredients and the mixing process need to be
qualified. It goes on with the moulding process which by itself has more than 100 parameters which need to be set correctly.
Here tool quality and longevity are of great help to maintain a stable moulding process. Subsequently there is the debinding
process which depends mainly on the design of the debinding equipment and the parameters, particularly the time and
temperature settings and the gas flow during the debinding cycle. The sintering process again depends on the design of the
sintering equipment and the parameters of the debinding cycle (time – temperature – atmosphere). Additionally, however, it
is of utmost importance to stage the parts correctly and consistently in the furnace. As already mentioned the MIM process
is a tricky process which requires a lot of process know how. Only if as many of the process parameters as possible are
controlled and held constant is it possible to produce optimal MIM parts.
There are an increasing number of equipment manufacturers along the whole process chain. It requires a lot of knowledge
to select state-of-the-art equipment. The same is true for the selection of the best suitable raw materials.
Fig. 3.6: MIM parts in the moulded, Fig. 3.7: MIM components for defence Fig. 3.8: Micro MIM components for
solvent debound, thermally debound and industry applications. (Courtesy Parmaco) various industry applications. (Courtesy
sintered stage. (Courtesy Parmaco). Parmaco)
During sintering the parts shrink by 12%
to 18% depending on the initial binder
content.
11
4. PROPERTIES OF MIM PRODUCTS
4.1 Density and residual porosity

MIM materials are usually processed to near full density. If not otherwise specified, ferrous MIM materials contain less than
3% residual porosity. These pores are finely dispersed, well rounded and isolated and have no access to the surface of the
component, so that MIM materials are impermeable to gases or liquids. The densities of MIM components shall be
determined according to ISO 3369 or by a gas pycnometer as stipulated between purchaser and producer.
4.2 Mechanical Properties

Due to the specific rules for shape design in MIM it is obvious that tensile test specimens which can be manufactured
without additional machining operations have distinct advantages both in terms of cost savings and technically. As MIM is
usually a net-shape or near-net-shape manufacturing process, the technical advantage is that the surface condition of the test
specimens is the same as that of the MIM component. This is why the MIM industry, at an early stage already, has developed
its own tensile test geometry. These so-called MIMA specimens, designated after the American Metal Injection Molding
Association by which they have first been proposed, were adopted by the ISO 2740 standard defining tensile test specimens
in powder metallurgy. European MIM manufacturers found that these test samples which have been designed with holes in
their clamping heads in order to facilitate clamping tend to fracture outside the gauge length if weld lines or cracks are
formed due to irregular mould filling. In order to avoid this problem, a MIM green part shape without holes was proposed
and specified in ISO 2740 (see Fig. 4.1). Sharp edges were avoided and only smooth transitions in cross section exist to allow
a uniform flow front for homogenous mould filling. The mould parting line is in the middle of the cavity.
0.1
0±
R3
Ø 0.04
+0.4
Ø 5 ± 0.02
37.6 0 R 7.5 ± 0.1

+0.5
75 0
5 ± 0.02
Fig. 4.1: Tensile test specimen according to ISO 2740
One of the strengths of metal injection moulding is the wide range of materials that can be processed. Many ferrous alloys
are processed by MIM, the most widely used being stainless steel. Heat treatable alloy steels are used for high strength
requirements. Soft magnetic alloys are also available. Non-ferrous materials include cobalt and nickel base alloys, niobium,
titanium, tungsten, copper and aluminium.
12
Table 4.1: Selected mechanical properties of MIM metals and alloys (HT = heat treated) [from ‘Injection Molding of Metals
and Ceramics’ by R.M. German & A. Bose, published by MPIF, Princeton, USA. Reprinted with permission.]
Table 4.1 lists mechanical property data that have been determined for a range of materials processed by MIM. More
mechanical and physical properties are given in the Global PM Property database an independent online resource which can
be found at www.pmdatabase.com
13
Global Powder Metallurgy Property Database

In 2005 the EPMA, together with the equivalent associations MPIF and JPMA in the US and Japan, launched the Global
Powder Metallurgy Property Database. Its website www.pmdatabase.com is an independent online resource and has
become a standard reference for designers willing to understand the properties of candidate MIM and PM materials for their
projects. A comprehensive collection of material properties is available for free for registered users. The materials can be
found through several search keys and information on suppliers is also available.
Ultimate Tensile Strength v Elongation

Graph: Example of plotted chart from GPMD
4.3 Fatigue Strength

The European MIM industry is undertaking efforts to provide design engineers with comprehensive material property data
as required for Finite Element Analysis (FEA). The determination of these characteristics, in particular fatigue properties, is
costly and time consuming. Only little data is available, for instance for the precipitation hardening stainless steel MIM-17-
4PH and the low alloy steel MIM-4340 which is generally heat treated by a conventional quench-and-temper process.
Fatigue properties were measured on tensile test specimens according to ISO 2740. The heat treatments recommended for
MIM-17-4PH and MIM-4340 were chosen in order to achieve a compromise between high strength and hardness as well as
sufficient toughness and ductility. MIM-17-4PH was solution annealed at 1050°C for 1 h in vacuum and aged at 480°C for 4 h
in air. MIM-4340 was normalised at 870°C for 20 min in vacuum, hardened at 840°C for 15 min in nitrogen, oil quenched and
then tempered at 425°C for 2 h in air.
The test results for MIM-17-4PH and MIM-4340 are shown in Fig. 4.2 and Fig. 4.3, respectively. Both results demonstrate that
MIM materials can have a promising fatigue strength which is comparable to wrought materials provided that similar heat
treatment is applied. Particular attention is recommended on mould preparation to obtain high surface quality for good
fatigue properties.
Fig. 4.2: Axial fatigue test plot for MIM-17-4 PH (R = 0), Fig. 4.3: Axial fatigue plot for MIM-4340 (R = 0)
(Courtesy of LNEG) (Courtesy of LNEG)
14
4.4 Heat Treatment

Many MIM materials (except for the austenitic stainless steels) may be heat treated to increase strength, hardness and wear
resistance. Ferrous MIM parts containing 0.3% or more carbon can be quench-hardened and tempered. Tempering is required
after quenching for stress relief, optimum strength and durability. The tempering temperature is a major factor in determining
the final strength and hardness of the material. These two properties can be varied over a wide range using different
tempering temperatures. Therefore, the hardness level acquired after heat treatment should always be stated with quenched
and tempered data. The mechanical properties given in this standard for the heat treated condition are minimum values
obtained at the lowest and the highest reasonable apparent hardness levels attained with different process temperatures.
4.5 Corrosion Resistance

To characterise the corrosion resistance of metals a wide range of test methods have been specified so far. The methods
include the neutral salt spray test, the synthetic sweat test, the artificial saliva test, the stress corrosion test, the susceptibility
to intergranular attack, passivation potential measurements or pitting potential measurements.
The test method recommended for corrosion tests on stainless steel MIM components is neutral salt spray (NSS) in
agreement with ISO 9227. It does not require specific sample geometry. It can be performed on any component shape and is
the most widely used and accepted corrosion test in industry.
Experience shows that a 200 h NSS test is sufficient to characterise the corrosion resistance of MIM-316L parts. For a

better understanding of the corrosion phenomena, the samples can be examined after 24 h, 48 h or 100 h. The general
requirement is a maximum corrosion of less than 10% of the surface. The acceptable corrosion resistance, however, should
be agreed between the MIM part manufacturer and the customer.
Interrelation between Corrosion Resistance and Other Properties

The corrosion behaviour of MIM parts depends largely on the manufacturing conditions. In general, it is possible to describe
the interrelations between the corrosion resistance and other properties such as porosity, density, phases in the
microstructure, grain size, or mechanical properties.
Porosity
The porosity itself has no noticeable influence on the corrosion resistance. However, the presence of open porosity and
significant surface roughness can lead to an increase of the corrosion of the material, mainly due to crevice corrosion.
Surface recesses can also be preferential sites for adhering impurities that can produce local corrosion.
Grain size
The best corrosion resistance is connected with the smallest grain size. Small grain structure is also essential for machining
and polishing of the materials. The conditions of sintering and cooling are important to reach a fine-grained microstructure.
Delta ferrite
The percentage of austenite transformed into delta ferrite during sintering is directly connected to the thermal cycle applied
for sintering, and then to the grain size. Most samples having a high or very high corrosion resistance contain delta ferrite
and have a fine grain size. However, a too large quantity of ferrite is detrimental if high quality finishing is required.
Heterogeneity on the surface due to delta ferrite can also have a detrimental effect on corrosion resistance.
Carbon content
The effect of the carbon content on the corrosion resistance of MIM-316L is well known. Low or very low carbon austenitic
stainless steels are required for a good corrosion resistance. Even with powder of good quality, if the material is
contaminated by carbon coming from the binder, its corrosion resistance can deteriorate.
Chromium content and chromium distribution

Chromium is essential for the formation of the passive film on the steel surface. If some chromium evaporates during
vacuum sintering, the superficial concentration of chromium can be reduced. The material is then easier to corrode. During
cooling, chromium can also react with carbon in order to form chromium carbides which precipitate at the grain boundaries.
They form discontinuities which allow corrosion to start. As the carbides precipitate more easily at the interfaces of ferrite
and austenite, a high quantity of ferrite should be avoided. The temperature should be reduced very quickly from 900°C to
600°C in order to limit the chromium carbide formation.
15
5. MIM DESIGN GUIDELINES

Proper design can greatly reduce costs related to secondary operations like machining, coining etc. and will help to avoid
processing problems. Generally speaking any shape that can be produced in thermoplastics by injection moulding can be
produced in metal by MIM. If the guidelines for plastic injection moulding of plastics are applied many of the design
requirements for MIM parts are met. There are, however, some economical limitations.
Fig. 5.1: A selection of MIM components which follow the guidelines for MIM design. (Courtesy Parmaco).
Part designers, who know the capabilities of the MIM process, are able to design functions into one part which would
otherwise only be possible by a costly joining of two or more parts made with other production methods. MIM parts can
add value to design at no additional cost.
5.1 Part design

Part weight
MIM is mainly used for rather small components. Ideal part weights range from 0.2 – 30 grams. Heavier or lighter parts can
be manufactured with restrictions. Some MIM parts can be as heavy as 200 grams and more. However, the larger the parts
the greater the proportion of the overall cost is attributed to the costly raw material. The total cost of the powder is a
linear function of the weight of the part whereas in the case of parts produced by machining solid bar stock, for example,
the machining cost increases mainly with machining time and to a lesser extent with material utilization. Parts which require
a lot of machining time are better candidates for MIM than, for example, turned parts which require little machining time.
Furthermore turned parts can be machined to very tight tolerances which is not possible to achieve by the MIM process
alone. Additionally heavy MIM parts have a less favourable behaviour during sintering and tend to require more rework.
Part size
Parts with overall dimensions of 0.2 – 30 mm are generally well suited for MIM if the design criteria cited below are
observed. Bigger parts use more costly material and furnace space and also the processing times are longer than for small
thin walled parts. Thus small parts, where the inexpensive MIM shaping process is favourable to costly machining, are better
candidates for MIM.
Wall thickness, coring
Uniform wall thickness is desirable in order to avoid distortion, internal stresses, voids, cracking or sink marks. Abrupt variations
in wall thickness can also cause variations in shrinkage during sintering, making dimensional control difficult. One method used
to attain uniform wall thickness is coring. Wall thickness should not be below 0.2 mm or above 6 mm. Minimized wall thickness,
coring and avoidance of material concentrations can also help to save material costs and processing time.
Fig. 5.2: Coring can be designed from different sides. The goal is always uniform wall thickness.
16
Holes and other internal geometries

The depth of blind holes formed by pins should be limited to five times their diameter, however, this rule is very general and
exceptions are possible if the flow is reasonably simultaneous all around the pin. Holes which are perpendicular to each
other cause sealing problems which result in burrs where the holes meet. By redesigning one hole to a D shape, the tool
will function better, be stronger and avoid flash. If this is not possible one pin will have to plunge into the other making the
adjustment of the tool more challenging.
Reinforcing ribs
Reinforcing ribs are an effective way to improve rigidity and strength in parts with thin walls. The thickness or width of ribs
should be half as thick or at least not exceed the thickness of the wall to which they are joined, to avoid sink marks. When
applying rib-structures to parts the material flow should be checked by mould flow analysis before building the tool.

Fig. 5.3: Ribs can help to strengthen the
overall geometry of the design.
Fig. 5.4: Ribs reduce weight and provide the required strength. (Courtesy Parmaco)
Transition from thick to thin, corners

In some parts, different wall thicknesses cannot be avoided. A gradual transition from one thickness to another reduces
stress concentrations and poor surface appearance (flow lines) due to turbulent flow conditions. In addition the part should
be gated at the thicker section to ensure proper packing of the feedstock. Furthermore, corners should be rounded in order
to avoid turbulent flow.
Fig. 5.5: Surface steps should be

avoided in order to improve the flow
of the material during injection and
thus to reduce internal stresses and
powder/binder segregation.
Support structures
In principle for MIM parts it is much preferred to have a level surface on which the parts can be positioned for sintering.
This avoids slumping and costly rework. Support structures can be used to minimize the slumping of the parts in the
sintering process. The drawback can be that these structures must be mechanically removed once the part is sintered.
However, if the support structures are designed in such a way that they do not affect the function of the part it may not be
necessary to remove them.
17
Reducing stress concentrations

Stress concentrations can be greatly reduced at no cost by rounding the corners and edges of the parts. In fact moulded
parts should not be designed with sharp edges since these hinder the flow of the feedstock and cause turbulent flow and
distortion. The ability to produce rounded corners is a clear advantage over machining since rounded corners can
sometimes not be achieved in machining or cause costs to rise.
Design of external threads
External threads can easily be moulded when certain guidelines are followed. The parting line leaves, however good the
mould is, always a fine protruding line on the surface of the moulded part. The protrusion is in the range of thousandth of a
millimetre up to several hundredth if the mould is worn. To ensure that the parting line does not interfere with the
functioning of the thread, the thread is flattened in the area of the parting line.
Fig. 5.6: The thread is flattened in the Fig. 5.7: Hollow MIM part with external
area of the parting line in order to allow thread (Courtesy Parmaco)
functioning of the thread.
(Courtesy Parmaco).
Design of internal threads

Internal threads are typically moulded by using automatic unscrewing devices which are part of the mould. Taping costs can
be avoided but the increased mould cost has to be considered.
The engagement of screws should not be longer than 10mm for both external and internal threads. Unfortunately the thread
pitch tends to vary slightly in MIM parts in the same way as other dimensions do in sintering. If the thread engagement is
long this will cause loss of clearance in the thread the longer the engagement is.
Fig. 5.8: Internal thread manufactured by Fig. 5.9: This connecting link incorporates the
MIM (Courtesy Parmaco) desirable design features of uniform wall
thickness, internal thread, reinforcement ribs and
identification marking (Courtesy Parmaco).
5.2. Mould design

Mould cooling design
Cooling is of utmost importance in order to avoid warpage due to internal stresses. The moulding cycle time depends not
only on the overall part geometry but also on the design of the cooling channels. The mould temperature usually is between
40°C and 150°C depending on the feedstock used and the wall thickness of the part.
Venting
In general, venting of the mould is an important aspect in injection moulding. If the mould seals too well, the air cannot get out
of the mould as it is filled with feedstock. Build-up of high internal air pressures can lead to formation of voids and pore chains
within the part or cause incomplete filling. This can be overcome by allowing the air to get out of the mould at the place where
it is filled last. For this purpose very fine venting channels are ground into the parting line or the mould is equipped with a
vacuum pump that ensures that there is no air in the mould during the injection cycle.
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Gating
All types of gating applied for plastic injection moulding can also be applied for MIM. The inflow of the feedstock should be
at a thick section rather than at a thin section. Additionally the material should not flow openly into the mould which would
cause jetting but rather be held back by some geometrical impediment such as a wall or a wide pin. Some of the most
popular gating systems are tunnel gates, film gates, tab/edge gates or sprue gates. There are various suppliers of valve gate
hot runner systems who offer their equipment for MIM moulds as well.
Mould parting lines

Parting lines originate from the closure plains of the injection and the ejection side of the mould. There will always be a
visible parting line on injection moulded parts unless the parting line is at an edge of the part. The parting line should not
run over a functional surface or a cosmetic surface of the part. Although sometimes a flat mould separation cannot be
realised it should be aimed for since stepped mould separations are more costly and cause the mould cavity to leak and
produce burrs.
Ejector pin marks

Ejectors are used to push the moulded part out of the cavity. Also here marks cannot be avoided. Therefore ejectors should
not be placed on cosmetic or functional surfaces. Usually ejectors are round but they can have different shapes.

Draft for demoulding, ejection
Draft is most welcome on injection moulded parts since ejection is eased. The number of ejector pins needed depends on
the geometry of the part and the rigidity of the moulded part and thus on the feedstock used.
Slides
Slides are used to shape part geometries which are not in the direction of ejection. They slide usually perpendicular to the
direction of ejection e.g. in the direction of the parting surfaces of the mould. Under certain circumstances they can slide in
any direction, however, only at considerably increased mould cost.
Undercuts
Undercuts which are not demouldable by slides cannot be moulded by MIM. MIM feedstocks are too rigid and too brittle to
allow for forced demoulding as it is possible with plastic components which are much more flexible.
Weld lines
A weld line is the area where two streams of feedstock meet. Depending on the feedstock used, the geometry of the part,
the mould design and the moulding parameters used weld lines can be avoided or at least minimized. Weld lines can have an
influence on the strength of the part but their influence is less pronounced than in plastic injection moulding because of the
subsequent sintering process.
5.3. Moulding simulation

Computer simulation can also be used for MIM. Principally the same programs as for plastic injection moulding can be used
for MIM, however, it is of importance that the characteristic feedstock property data is loaded into the program. Software
packages such as SIGMASOFT or MOLDFLOW are available and give good agreement with reality. The simulation is suitable
to optimize the part design, the mould design and to plan the moulding process. Work on mould filling simulation software is
continuously progressing and models are today able to predict even powder binder segregation effects by taking into
account that MIM feedstocks are multi-phase continua with powder particles of varying size.
The moulding simulation can also be used to predict and optimize the effect of the mould cooling design, gating, venting and
weld lines.
Fig. 5.10: Mould filling simulation is Fig. 5.11: Distortion can also be Fig. 5.12: Weld lines can be predicted by
widely used to predict the filling and predicted by good simulation software. simulation. If needed the geometry or the
cooling behaviour (Courtesy Parmaco) The distortion can be shown by scaling gating position can be changed to bring
the distortion misfit (Courtesy Parmaco) the weld line to an uncritical position
(Courtesy Parmaco)
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5.4. Dimensional accuracy of MIM parts

Linear dimensions
In practice it is often not well defined what designers mean when they talk about tolerances unless one specifically addresses
this issue. If they have statistics and the definition of process capability (cpk) in mind it is far harder to meet a specified
tolerance. This approach becomes more common these days. The old fashioned approach is to measure just a few parts of a
batch. Then only the individual measuring results have to be within the given tolerance. This second approach is far less
stringent. Manufacturers and likewise end users are therefore well advised to define the tolerance issue.
The dimensional accuracy of MIM parts depends on many factors. The most important is size since the dimensional accuracy
goes with size, meaning that the bigger the dimensions the wider the required tolerance range.
As can be seen in Table 5.1 the required tolerance range for MIM is very much dependent on the cpk level specified.
Furthermore it depends on the processing conditions and the design of the parts as discussed above in the section Part
Design. In Table 5.1 the required tolerances under standard processing conditions and best practice conditions are compared.
Best practice conditions are given when the design of the part is ideal for injection moulding and staging in the sintering
furnace. Standard conditions are given when the part is not ideally designed for MIM.
In reality the required dimensional tolerances of a given part vary anywhere between the values given for standard
conditions and best practice conditions. Some dimensions will have a narrow scatter range whereas others will have a wider
one. When cpk is required each dimension has to be discussed carefully and it is mandatory to optimize the part design as
much as possible. Narrow tolerances can be achieved on critical dimensions under favourable conditions. Mould parting lines,
varying wall thickness and other factors discussed above will adversely affect the dimensional accuracy of the part.
Typically required tolerances for MIM under Typically required tolerances for MIM under best
standard conditions practice conditions
Required Required Required Required Required Required
tolerance range tolerance range tolerance range tolerance range tolerance range tolerance range
for no cpk for cpk 1.33 for cpk 2.00 for no cpk for cpk 1.33 for cpk 2.00
Dimension mm mm mm mm mm mm
< 1mm 0.021 0.033 0.045 0.014 0.020 0.026
1 - 2mm 0.040 0.064 0.088 0.026 0.038 0.050
2 - 3mm 0.055 0.091 0.127 0.034 0.052 0.070
3 - 6mm 0.10 0.17 0.24 0.06 0.09 0.13
6 - 15mm 0.24 0.42 0.65 0.14 0.23 0.32
15 - 30mm 0.49 0.85 1.21 0.28 0.46 0.64
30 - 50mm 0.79 1.39 1.99 0.44 0.74 1.04
Dimension % of dimension % of dimension % of dimension % of dimension % of dimension % of dimension

< 1mm 2.1 3.3 4.5 1.4 2.0 2.6
1 - 2mm 2.0 3.2 4.4 1.3 1.9 2.5
2 - 3mm 1.8 3.0 4.2 1.1 1.7 2.3
3 - 6mm 1.7 2.9 4.1 1.0 1.6 2.2
6 - 15mm 1.6 2.8 4.0 0.9 1.5 2.1
15 - 30mm 1.6 2.8 4.0 0.9 1.5 2.1
30 - 50mm 1.6 2.8 4.0 0.9 1.5 2.1
Table 5.1: Required tolerance range for standard and best practice conditions for different process capability levels
Geometrical tolerances
Table 5.1 and Figure 5.13 address linear dimensions which are not influenced by distortion. Distortion has a strong influence
on straightness, flatness and geometrical tolerances and is difficult to put in general numbers.
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Angular tolerances
Angular tolerances are particularly difficult to predict since the part geometry and both the moulding process and the
positioning of the parts during sintering can cause distortion.
Surface roughness
The surface roughness of the parts depends on the powder grain size, the relative sinter density and the roughness of the
mould surface. In general values of Ra < 1.2 can be achieved. If Ra < 0.8 is required polishing by tumbling is necessary.

Fig. 5.13: Comparison of ISO Standard 22768-1 with different MIM processing capability levels
Radii
Generally radii should be chosen to be as big as possible in order to improve the feedstock flow during moulding but radii as
small as 0.05 mm can be achieved. Depending on the mould design and the feedstock used even smaller radii can be possible.
5.5. Comparison of MIM with competing processes

MIM is a process that is used when high volumes of parts need to be manufactured. When the number of parts is low,
typically below 10’000 parts, mould costs and development costs adversely affect the competitiveness of MIM. Every process
has its limitations. It is the overall benefit and the added value which is significant for the selection of a production process.
MIM can be very helpful in adding value.
MIM vs. Precision casting
Generally MIM is used for parts under 30g whereas precision casting tends to be more competitive for bigger parts. MIM is
generally more accurate than precision casting and is superior in reproducing fine geometrical details.
MIM vs. Press and Sinter
Press and sinter is a relatively cheap method of producing metal components with a density usually in the range of about
90% of the theoretical density of the alloy used. The shaping process consists of uniaxial compression of metal powder into a
die. Therefore no undercuts are possible. MIM has the advantage that truly three dimensional parts with complex shapes can
be moulded. MIM is generally more expensive but produces parts with higher density. Therefore whenever geometry can be
made by press and sinter MIM will be more expensive.
21
MIM vs. machining

Machining has an edge over MIM concerning cost when very accurate parts with dimensions greater than 15 mm are needed
because MIM parts need costly rework to match the accuracy of machined parts. Machining has also an edge when only a
small number of parts are needed. Although small parts can be produced very accurately with MIM the not existing mould
and development costs are in favour of machining. If, however, parts are needed in high volumes with tolerances that can be
met by MIM, MIM is the production method of choice.
MIM vs. plastic injection moulding
If mechanical properties of metals are needed plastic injection moulding cannot be applied. If the properties of plastics fulfil
the purpose it should always be chosen because it is much cheaper than MIM. Thus there is no overlap of plastic injection
moulding and MIM.
MIM vs. Zn and Al die casting
The same is true for MIM vs. die casting. MIM will only be chosen when the mechanical properties of die cast components
are not suitable for their function.
MIM vs. cold forging
Cold forging is a process applied for mass production of very high volumes of parts. MIM can only compete when the
geometry is complex enough to create very high die costs.

MIM vs. stamping or fine blanking
Stamping and fine blanking use sheet material which is quite inexpensive. As long as the geometry of the part can be made
by these processes MIM is not competitive.
Over all MIM is a problem solver that comes into play when the set of requirements cannot be met with cheap processes
or when the geometry is such that MIM has an edge despite of its relatively high cost.
6. INTERNATIONAL STANDARDS FOR MIM
6.1 Objective
The international standard activities on MIM are intended to provide the design and materials engineer with the necessary
information for specifying the materials of structural components manufactured by MIM. It defines material designations, limits
of chemical compositions, physical and mechanical properties as well as testing conditions. Its main purpose is to avoid
misunderstandings between the manufacturer and the purchaser of MIM parts and it should assist both in the effective selection
of appropriate materials for given MIM products. MIM standards must not be applied to parts manufactured by classical powder
metallurgy routes such as the press-and-sinter or powder forging technologies. A comprehensive overview on the all relevant
standards for MIM was recently published in the industry magazine PIM International, Vol. 11, No. 1 in March 2017 and includes
the progress to-date and future challenges for MIM.
6.2 MIM material designation

The European MIM industry has long recognised the need for the development of international standards. Early joint efforts
were focussed on the development of an ISO standard for MIM materials. The outcome of a series of meetings and discussions
with the North American and Japanese trade associations as well as the relevant ISO sub-committee was the ISO standard
ISO 22068 Sintered Metal Injection Moulded Materials – Specifications published in 2012. It covers material designations of MIM
materials. Similar general MIM standards were published by the Metal Powder Industries Federation MPIF as Standard 35 in
1993 (revised in 2016) and ASTM International as B883 in 1997 (revised in 2015).
Materials produced by MIM shall be designated by the prefix 'MIM-' followed by the designation of the alloy grade. Where
applicable, the designation of the alloy grade follows the well-established designation of wrought steels; e.g. the AISI-designated
stainless steel 316L produced by MIM is designated as MIM-316L, whereas the DIN-designated 42CrMo4 produced by MIM is
designated as MIM-42CrMo4. If possible, both designations, AISI and DIN, may equally be applied such as MIM-42CrMo4 =
MIM-4140. Alloys with no corresponding wrought steel of the same composition are usually designated by an abbreviation of
their alloy composition. The alloy Fe-2% Ni, for example, has the designation MIM-Fe2Ni.
22
6.3 Standards on mechanical properties

In the main MIM standards the concepts of minimum and typical mechanical property values is followed for structural
applications. The minimum values for MIM materials are expressed in terms of yield strength (0.2% offset method), ultimate
tensile strength and elongation (in percentage) in the as-sintered or heat treated condition. In the heat treated condition,
minimum property values are given for the lowest and the highest reasonable apparent hardness. For structural MIM parts the
most applied standards are:
• ISO 2740 - Sintered Metal Materials (excluding Hardmetal) - Tensile test pieces
• ISO 3369 - Impermeable Sintered Metal Materials and Hardmetals - Determination of Density
• ISO 6892 - Metallic Materials - Tensile Testing at Ambient Temperatures
Tensile properties obtained from test specimens machined from commercial parts or from non-standard MIM test specimens
may vary from those obtained from specimens prepared according to ISO 2740. Therefore, evidence of mechanical properties
for a particular component - unless otherwise agreed between the manufacturer and the purchaser - shall only be obtained by
testing tensile specimens according to ISO 2740. The specimens should be manufactured from the same batch of material as the
parts, must have the same density and must be sintered and heat treated along with the production parts.
6.4 Standards for non-ferrous MIM materials

A few standards were also defined especially for non-ferrous MIM materials as titanium, the titanium alloys MIM-Ti-6Al-4V,
the cobalt-chromium alloy MIM-Co-28Cr-6Mo and the nickel base alloy MIM-IN718 which are listed below:
• ASTM F2989 - Standard Specification for Metal Injection Moulded Unalloyed Titanium Components for Surgical Implant
Applications
• STM F2885 - Metal Injection Moulded Titanium-6Aluminum-4Vanadium Components for Surgical Implant Applications
• ASTM F2886 - Standard Specification for Metal Injection Moulded Cobald-28Chromium-6Molybdenum Components for
Surgical Implant Applications
• SAE AMS 5917 - Metal Injection Moulded Nickel Based Alloy 718 Parts Hot Isostatically Pressed, Solutioned and Aged
6.5 Standards for testing MIM parts

Testing methods for MIM materials and components were also specified in several standards which provide an essential basis for
comparability of material properties obtained by MIM. The standards were comprised by the MPIF as the specific volumes 50,
59, 62 and 63 for tensile tests, Charpy Impact testing, corrosion resistance and density determination by gas pycnometry.
6.6 Further standards relevant for MIM

In addition to the standards particularly for MIM parts, there are several existing ISO standards for metal powders, sintered
metal parts and testing methods which are also relevant to MIM. These ISO standards include:
• ISO 4498 - Sintered Metal Materials, excluding Hardmetals - Determination of Apparent Hardness and Microhardness
• ISO 2354 - Powders for Powder Metallurgical Purposes - Sampling
• ISO 2738 - Sintered Metal Materials, excluding Hardmetals - Permeable Sintered Metal Materials - Determination of Density,
Oil Content and Open Porosity
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7. RECENT DEVELOPMENTS FOR THE MIM PROCESS
7.1 Two Component MIM

Two-component Metal Injection Moulding has been developed as a manufacturing route for the fabrication of bi-material
MIM parts. The major advantage of two-component MIM is the direct combination of two materials with different properties
in a single production step, therefore eliminating the need for a subsequent joining process. The variety of parts that can be
manufactured range from hollow items with complex internal structures to flexible, non-detachable joints and combinations
of different materials in the same MIM part.
The objective in all cases is to manufacture industrial parts with enhanced functionality at favourable costs. Several successful
case studies with new material combinations as titanium & steel, CoCr & steel and magnetic & non-magnetic stainless steel
(see Fig. 7.1) were recently published in the Metal Powder Report, Vol. 71, No 6, Nov / Dec 2016. The case studies
demonstrate the potential of bi-material applications for MIM parts. For instance, parts that are subject to wear can be
strengthened by using a harder or more wear resistant material at only critical areas and thus having a tailor-made
component for an individual application.
Several material and processing characteristics are to be considered to produce MIM parts by this route. The two materials
must be sintered in the same furnace under the same sintering atmosphere and thermal conditions. During mutual sintering,
also called co-sintering, it is essential that the two materials
shrink with a similar shrinkage rate so that delamination and
cracking is avoided. Also the diffusion of alloying elements
along the boundary needs to be kept at a certain extend to
prevent that unwanted phases are formed which could reduce
the material properties at the interface.
First two-component MIM parts produced on industrial
standards are available on the commercial market. For instance,
the company Schunk Sintermetalltechnik GmbH, Germany,
presented a two-component pin at the World PM 2016
Congress & Exhibition that combines wear resistant and
weldable materials for automotive applications (see section
Case Studies). Due to its unique capability to enable different
Fig. 7.1: Magnetic/non-magnetic valve sleeve as green and material properties within the same MIM part without
sintered two-component MIM part. additional assembling operations, two-component MIM will
(Courtesy Fraunhofer IFAM) certainly stimulate the potential market for the MIM industry.
7.2 Binder Jet 3D-Printing for Prototyping and Small Scale MIM Production
Binder Jet 3D-Printing is an Additive Manufacturing (AM) process in which powder material is deposited in thin layers and
selectively joined according to CAD data, hence parts are generated without the need for special tools or moulds. But
instead of melting the material, as it is done in Selective Laser Melting (SLM) or Electron Beam Melting (EBM), in the Binder
Jetting process the metal powder is joined by an adhesive ink and after thermal debinding either directly sintered to full
density or partially sintered and infiltrated. These two process routes offer a wide choice of materials and flexibility in
attainable properties.
Since the process chain for Binder Jetting and sintering to full density is in general similar to the MIM process, this
technology holds the potential to be used in prototyping or small scale production for MIM parts. A printed prototype of a
MIM part could be used to test the sintering conditions, adjust the geometry to the shrinkage and characterize the
mechanical properties, even before the mould is produced. This could significantly shorten the time required to design new
MIM components, develop tools or alter the parts to specific customer needs.
Fig. 7.3: Earring by binder jet 3D-printing of stainless Fig. 7.3: Wrench by binder jet 3D-printing of stainless
steel 316L (Courtesy Fraunhofer IFAM) steel 420 (Courtesy Fraunhofer IFAM)
24
Already today printers for Binder Jet 3D-Printing are commercially available up to production size systems. So far, the
machine manufacturers qualified the process only for few materials: different steel grades (420, 316L and 17-4PH), Nickel-
base alloys (IN 625 and IN 718) and Cobalt-Chrome. But the range of available materials is expected to grow fast since
theoretically all sinterable materials can be used in Binder Jetting systems. Additionally, the particle size and shape required
for Binder Jetting is similar to MIM, hence one can use readily available powder grades.
At the moment, the densification, dimensional accuracy and surface quality achieved by Binder Jetting are not as good as in
conventional PM processes. Further research and development projects are necessary to optimize the process parameters for a
broad range of materials and to improve the green density and packing homogeneity. However, with improvement of the part
properties and process stability Binder Jet 3D-Printing will offer new opportunities and markets for the MIM industry.
8. SUMMARY
This guide is intended to give an overview of the benefits and capabilities of the MIM process. Before a particular grade of
material is selected, a careful analysis of the part design and its end-user requirements is necessary, including dimensional

tolerances and an analysis of part design versus tool design. The final property requirements of the finished part should be
stipulated between the manufacturer and the purchaser. Issues such as static and dynamic loading, wear resistance,
machinability and corrosion resistance may also be specified.
To select a material optimum in both properties and cost effectiveness, it is essential that the part design and the application
might be discussed with the MIM part manufacturer. A list of MIM part manufacturers can be found online at the EPMA
website www.epma.com. Further useful information concerning the MIM process, MIM materials and the design of MIM
components can be found at www.designforpm.net and www.pmdatabase.com.
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Global Powder Metallurgy Property Database
Introducing the latest material

database development for
Designers and Engineers worldwide
The Global Powder Metallurgy Property Database – a special online resource
The Global Powder Metallurgy Database (GPMD) was created in response to the absence of a readily accessible source
of design data which was acting as a significant impediment to the wider application of PM products. The database was
the result of a global collaboration between the three major regional trade associations: EPMA (Europe), MPIF (North
America) and JPMA (Japan). Since its launch in 2004 the content has been steadily increased to a total of nearly 4000 lines
of high quality data.
The GPMD provides physical, mechanical and fatigue data for a

range of commercially available PM materials. Originally covering the
mechanical and physical properties of PM Steels and Stainless Steels
from 6.4 gm/cc upwards, Powder Forged Steels, non ferrous materials
and bearing alloys over one thousand new lines of data have been
added since the launch. These now additionally cover ferrous and
non ferrous MIM materials, fatigue endurance limits and SN curves.
A well tested system of data collection and validation means that

the maximum amount of technical information can be displayed
without compromising the source and confidentiality of donating
organisations. Current areas to be further developed include
expanding the available MIM data, obtaining and verifying data from
the PM HIP sector and additional data for fatigue properties. With
registered users from all parts of the world the database provides a
significant resource to a very wide range of designers and engineers
who may not be familiar with PM technology.
The free to access database allows detailed searches on physical and mechanical properties
to be made and results downloaded as either spreadsheets or into well-known FEA packages
such as Abacus or MSC. The associated website at www.pmdatabase.com also provides
background data on the PM process and designing for PM. Users can also view a list of
contributing PM parts makers with contact details. For more first class data please visit:
www.pmdatabase.com
Visit the website for more information on:

• How it can benefit you
• How to access it
• How it works
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The information below is provided by third parties and although EPMA does its best to
9. CASE STUDIES ensure the case studies are accurate it is not liable for any mistakes or wrong information.
Aerospace
HPC-VANE
Schunk Sintermetalltechnik, Germany
The HPC-vane is the first serial
MIM application in high pressure
compressor (HPC) of a turbine
engine. The part substitutes a
forged part without any reductions
in performance. Schunk as the MIM producer had to develop
based on its standard MIM process a technology that fullfills
all requirements of aerospace industry in quality assurance,
reproducibility and traceability. The most important challenge
was the guarantee the shape stability of the aerofoil and the
prevention of contamination of the material with carbon,
oxygen and nitrogen along the process from powder

production up to the sintered part.
Automotive
2C-PIN BRAKES AND
Schunk Sintermetalltechnik, HYDRAULIC SYSTEM
Germany Mimecrisa, Ecrimesa Group,
2C-Pin is the first serial part Spain
in the world produced by Plastic substitution for better
Metal Injection Moulding Strength and other MIM
of two different materials. parts were transfered from
A customer problem was solved: combination of wear machining.
resistance in a wide range of temperature and weldability of
materials in one complex part.
The innovation was to modify the two alloys to get nearly
the same sintering behavior. Cracks are fully avoided and
between the two components a continuous gradient in
chemical composition instead of an abrupt joining zone can
be determined. Schunk opened a new area for PM business
with big growing potential.
BURN CHAMBER COVER

GKN Sinter Metals, Germany Gevorkyan, Slovakia
This part weighing The Cover is a complicated
approximately 40g is the part, not only from shape
burner chamber of an point of view, but also
automotive heater used in because of customer/
cars and trucks. The part is consumer aesthetic demands.
made from MIM-316L stainless steel at a minimum density of The part has to be visually good-looking. No visual marks
7.3 g/cm³. should occur. Made on complex MIM tool with ejection
Besides resistance to heat and oxidation, gas tightness is packet fixed on half of the mold. Volume per annum: 13000+.
required. Only the outer diameter is finish machined for a
close fit. Special design features include a lateral through
hole at a 9º angle and the engravings on the inside which are
produced during moulding.
28
CYLINDRICAL CAM DRIVING BUSH –

WITH GEAR SEAT BACKREST
Gevorkyan, Slovakia ADJUSTMENT
Two plates, two cavities Schunk Sintermetalltechnik,
MIM mold with cold runner Germany
system and edge gate. This part is a central element
Standard injection pressure of seat backrest adjustment
and sintering temperature according recommendation from in automotive applications made of MECO12 (1.0618) with
material data sheet a weight of 21,2g. The part is injected to be ready to use and
will be assembled with a rubber part for limit stop damping.

GDI PUMP GUIDES FOR
COMPONENTS AUTOMATIC
INDO-MIM PVT Ltd. India ASSEMBLY LINE
Four MIM parts – blank ITB, Netherlands
discharge check, stop discharge This set of 3 parts is used
check valve, valve discharge in an automatic assembly
check, and CRV spring seat – line to mount electric
that go into a device that controls fuel flow in Gasoline Direct connectors. Weighing between 4,63 and 7,25 grams, they
Injection (GDI) pumps. Three of the parts are made of 440C replace conventional parts machined out of solid material.
stainless steel, while the fourth is made of 17-4 PH. For the material a 100Cr6 alloy was selected, sintered to a
The extremely complex geometry of the blank discharge check, density of
with the intercrossing of holes, required tooling with six side > 7,5 g/cm³. After heat treatment a hardness of 62 HRC was
cores, three of which move at different timings. The annual obtained.
volumes are close to 1.2 million pcs a year each. The parts are The metal injection moulding route allowed for a light, thin
designed for MIM. All the four parts go into a device which wall and more complex design, introducing rectangular and
controls the fuel flow in Gasoline Direct Injection (GDI) Pumps square holes. Compared to conventional machining operations
of passenger cars. production cost per part was reduced by a factor 40! Due
to this substantial cost reduction the MIM production route
is preferred even for small quantities (several 1000 sets per
GUIDES FOR ONE PIECE NOZZLE

RETRACTABLE CAR AMT PTE LTD
TOP SYSTEM The metal injection molded
Schunk Sintermetalltechnik, One Piece Nozzle has
Germany pushed this technology
to greater heights. It is an
These parts are made of impossible task to produce
MECO44 (1.5735). In a this product near net shape using other conventional
CSC-car top they are applied to lock and guide the lift gate. methods. Possible methods will be brazing of multiple
Delivery of these parts is completed with a sliding lacquer machined components, which will end up with high material
coating. wastage and high cost. The MIM One Piece Nozzle produced
good finish with complex internal channel in a sustainable
and economical way. This product has open up an entirely
new application for MIM process capability, and definitely the
most complex part that we have ever produced.
29
Automotive
PISTON COOLING PLANET CARRIER
NOZZLE WITH SUN GEAR
GKN Sinter Metals, Germany Parmaco Metal Injection
A MIM part and a tube are Molding AG, Switzerland
assembled and brazed to Planetary gears are widely used
form this nozzle which cools to reduce the rotary speed
the piston in a V8 engine. The and thus increase the rotary
nozzle is built into the engine block and directs a defined torque of DC motors. There is a shift to ever smaller motors and
oil jet stream onto the bottom side of the piston. The close consequently smaller planetary gears.
dimensional tolerances and the slot required for brazing can MIM proved to be the most cost effective manufacturing route
best be produced by MIM. The material is MIM-Fe2Ni at a for the high production volumes of 12 million Planet-Carriers
minimum density of 7.5g/cm³, the part weight is 11g. with Sun Gear per year. Instead of assembling 5 parts, microMIM
can produce the Planet Carrier with sun gear in one part. Cost
savings are in the range of 40%. This microMIM part weighing
0.076g. The powder is mixed of carbonyl iron powder, Nickel
powder and a 316L master alloy. After sintering the parts are
vacuum hardened and polished. Density 7.8g/cm³, hardness 450-
550HV1, surface roughness better than Ra 0.4.
ROTARY KNOB SENSOR HOUSING

OBE Ohnmacht & Sintex a/s, Denmark
Baumgärtner GmbH & Co. KG The part was previously
The component was designed produced in plastic, but more
to emphasize the lightweight demanding requirements led
and complex construction to the consideration of a
possibilities of MIM combined solution in metal. There was
with the filigree impression of titanium. The idea is to create an a wish for greater strength because the sensor housing is
innovative rotary knob for the automotive industry in high end primarily used for industrial purposes in environments that
cars. In cars full of touch screens this titanium knob should be a degrade plastic materials both thermally and chemically.
highlight design element giving an air of exclusivity and luxury as With the technology behind MIM, we were able to produce
well as a cool touch. a sensor housing with the same geometry as plastic, but
The rotary knob is supposed to be equipped with a round with the same strength as steel. The entire sensor housing
Swarowski glass component to be fixed on top of the part. is produced as a single component – in a single process.
Therefore, tolerances in the diameter are important to be kept The sensor housing is fited into a flow pipe that is used to
in a serial production. Thanks to the open construction of the measure flow and pressure in pipe systems. The housing
part cool or warm light elements enable additional high class is used to protect and enclose the electronics for the
atmosphere. measurements.
In the inner center logos can be easily integrated directly in the
STEERING LEVER STEERING LEVER

Schunk Sintermetalltechnik, NNF TECH PVT. Ltd, India
Germany This component was
This part is supplied for use migrated from plastic. Its
in an automotive steering application requires the
assembly. It is made from component to withstand
MIM-4340 low alloy steel significantly high pressure
and hardened after sintering. The lever is electroplated with originated from passing
zinc and black chromatized in order to provide the required fluid with a certain high temperature. The customer was
corrosion resistance. experiencing leakage in plastic component on lesser wall
thickness areas. Hence, it was converted to MIM.
30
Consumer Goods
BIKE RATCHET CAMERA TRIPOD BODY
Mimecrisa, Ecrimesa Group, Spain MIMest Spa, Italy
These components are A set of four pieces that compose
responsible for the transmission a stainless steel tripod for
of movement between the pedals cameras with excellent corrosion
and the wheel of a bicycle. It properties as the tripod is
is a system of transmission of intended for outdoor demanding
magneto-mechanical movements applications. The most impressive
and the coupling of both part of the set is the tripod body:
components is essential for proper work. The main difficulty a 260g stainless steel, AISI 316, piece produced using MIM.
at the time of the development of the parts was to achieve This austenitic stainless steel was chosen for its corrosion
a perfect filling in such fine teeth and achieve a perfect resistance. The as-sintered part is then subjected to
coupling of both parts. Therefore, we have very strict machining to remove sintering built-in supports, to resize

dimensional requirements. The main advantages obtained lateral holes and realise the thread. The part is then electro
doing these parts in MIM technology are the cost savings in polished to reach its final and pre-assembling stage.
manufacturing, mainly saves operations of machining and we
obtain parts with good mechanical properties for the work
of the parts.
DOOR HINGES SPORTS GOODS AND

Mimecrisa, Ecrimesa Group, HAND TOOLS
Spain Mimecrisa, Ecrimesa Group,
When we talk about the Spain
possibility of manufacturing These parts for personal and
complex parts in MIM professional hand tools and
technology, these parts sports goods are made from
reflect what we mean perfectly. Knurling, text, thin walls and case hardened steel like MIM-8620 with a surface hardness of 700
the extremely complex shape in terms of support for sintering, HV10 and fully hardened steel (arrow tip) MIM-Fe8Ni0.6C with a
make these pieces a manufacturing challenge. The main difficulties hardness of 50 - 55 HRC.
found at the time of the development of the parts were the
correct design of the geometry, especially to avoid deformations A traditional costly manufacturing route of bending, welding and
and cracks when we sintered the parts. It was necessary to machining has been replaced by MIM. Close tolerances of ± 0.3
redesign both hinges to avoid defects. The main advantages % are achieved, thin walls of 1mm ending in sharp corners and
obtained doing these parts in MIM technology are the cost an external thread are possible directly by using MIM technology
savings in manufacturing, which saves operations of machining and (see arrow tip).
secondary welding and, therefore, we obtain parts with better final
mechanical properties. The parts are hinges used in glass and wood
doors and they can open doors up to 270º.
SOULBUDDY TOURING BINDING

OBE Ohnmacht & ASSEMBLY
Baumgärtner GmbH & Co. KG Parmaco Metal Injection
Together with the University Molding AG, Switzerland
of Design in Pforzheim/ The special challenge in the
Germany OBE developed an design of a touring binding is
exclusive earbud concept that it must be equally suited
based on the MIM-technology. Two industrial design students for uphill walking on skis and downhill skiing. It guarantees
became the task to create different complex earbud housings the same safety level as conventional downhill bindings. One
made from metal. Target for them was to utilise as much as special challenge with touring bindings is that low weight is
possible the benefits of the design freedom of the MIM- of even bigger importance than for downhill bindings.
technology by considering at the same time ergonomic
aspects of an earphone. Only the relevant inner components The challenge during the development phase was to address
of an earbud gave the design limitations. On the other hand space constraints, weight constraints, functionality and ease
the intention was to create also a more visible and valuable of use. MIM proves with this challenging application that it is
product compared to small and rather invisible plastic capable of achieving not only excellent functional properties
earbuds. but also cost savings of 50% compared to competing
manufacturing technologies.
31
Consumer Goods
WATCHCASES
ETA SA Fabriques d'Ebauches,
Switzerland
ETA turned to metal
injection moulding for its
range of SWATCH IRONY
watchcases because of
significant cost savings compared with the traditional
manufacturing process. The cases which follow the same
basic design as for the plastic SWATCH, are made of stainless
steel MIM-316L. Density after sintering is 7.90 to 7.95 g/cm³.
Generally, tolerances must be maintained at ± 0.02 mm. All
watchcases are polished or brushed to provide the excellent
surface finish required by marketing. Particular attention has

been paid to health and safety issues, such as the prevention
of nickel allergy by avoiding high nickel contents; only 316L is
permitted for watchcases and watch components.
Medical
BASE AND JAW BODY OF WATCH
FOR ORTHOPEDIC WITH BOTTOMS
APPLICATIONS Gevorkyan, Slovakia
MIMEST Spa, Italy MIM part corpus special
body of watch for blind
Originally designed for
patients with bottoms.
machining. Switch to MIM for
Unique shape without glass
economical reasons.
for blind patients. Anti-
Redesigned in some parts for a new restyling. It has a allergic material. Part produced together with side bottoms.
sandblasted finish to it and its final weight is 922-968 grams. Without additional machining.
BOLT COSMETIC
Iscar, Israel SURGEON DEVICE
This part is used in a medical Mimecrisa, Ecrimesa Group,
device and made from MIM Spain
17-4-PH stainless steel. This component particularly
Usually in conventional highlights for its complexity
manufacture process such of form such as thin walls. The
kind of articles are assembled from two parts, pin and main idea of the customer was to make the part by machining,
body, that are made by machining. MIM technology allows but after refusing several manufacturers of machining, the
the production of the part in one piece, saves material and customer turned to MIMECRISA to raise production by MIM
decreases the cost of the parts for customer. technology, assuming the costs of making the mould for short
production batches.
The main difficulties found at the time of development of the
part were a correct mould design, especially when ejecting the
part from the mold without breaking the most fragile areas of
the part. The main advantages obtained by making this part with
MIM technology are cost savings compared to manufacture by
machining, saving secondary machining and welding operations,
and therefore better final mechanical properties. The part is the
head of a laser surgery machine.
32
Medical
COMPONENTS FOR NECK LINK
PROSTHETIC LIMB Parmaco Metal Injection Molding AG,
GKN Sinter Metals, Germany Switzerland
Three MIM components; Heine has been producing its

a blocking plate, blocking Diagnostic Center EN 100 since
hook and a twin connecting 1998. It contains among other
plate are used in a new instruments an otoscope an
prosthetic knee produced by Otto Bock. The blocking plate ophtalmoscope and an extension
and blocking hook are assembled together in the knee joint unit. All instruments use the same
as a unit. They are used to prevent accidental variable knee holder.
flexion when necessary as a protection of the knee joint. One of the critical components of this holder is the patented
In this case the blocking hook which is rotatable, snaps in on automated locking device that allows for one handed opening
the blocking plate in the extended position and blocks the and closing of the locking mechanism, and is still considered

flexion of the prosthesis. When the blocking hook is lifted in an ideal solution for the precise fit of the instruments.
the extended position of the prosthesis by means of a lifting
device, the flexion of the knee prosthesis is activated and the
patient can sit down, for example.
Other
CARTRIDGE FOR CATCHER,TENSION
SLOTTING CUTTER BAR & NEW BASE CAP
Iscar, Israel INDO-MIM PVT Ltd.
This component made from Originally designed for
4340 steel is part of the machining. Switch to MIM for
clamping device – changed economical reasons.
pocket - for full slot These parts are converted
adjustable slotting metal cutters. These slot milling cutters to MIM process from the
use cutting inserts with four cutting edges. They are suitable conventional manufacturing process. Previous process
for high table feeds resulting in increased productivity. involved machining, welding, PM and fastening. Indo-MIM
Compared to machining, using MIM technology in designers worked with the customer and completely re-
combination with heat treatment has made a cost reduction designed the 3 parts to make them cost effective via MIM.
of more than 50% possible while retaining similar physical The redesigned MIM products helped customer avoid field
properties. Parts cost reduction of more than 50% with failures and minimize the supply chain.
similar physical properties.
COVER DOUBLE HAMMER

Mimecrisa, Ecrimesa Group, Spain Mimecrisa, Ecrimesa Group,
We found the main difficulty at Spain
the time of the development of The part is a double
the parts in the injection process, hammer for a double
as they are parts of 1mm thick barrel gun, which has led
in green stage and the correct significant savings in terms
filling of the parts is difficult. It is of manufacturing costs to
also very important to choose a the customer, especially in
good sintering position to avoid deformations in parts of such machining operations.
low thickness. Another difficulty at the time of manufacture
is to avoid deformations when we hardened parts of such
low thickness (0.8mm). Here in MIMECRISA, we have heat
treatments in house, therefore we have the possibility of
optimizing heat treatments to reduce deformations in parts.
The main advantages obtained by making these parts in MIM
technology are the cost savings in manufacturing and high
mechanical strength and high yield strength for a geometry of
such low thickness.
33
Other
LOCKING LEVER NOZZLE
Iscar, Israel Iscar, Israel
This part is used in cutting This part is used for
tools locking mechanism generating a powerful, quiet
and provides locking force and laminar air stream.
for clamping an insert into The part is made from MIM
different types of turning 17-4PH stainless steel with
cutting tools. precise narrow trapezoid slots and customer's logo.
The parts is designed specifically for MIM technology and
produced from MIM 4340 low alloy steel with heat treatment
to the hardness of 45-48 HRC.
OUTPUT SHAFT, SAW BLADE

LEVER & COVER FASTENER
INDO-MIM PVT Ltd. Parmaco AG, Switzerland
Made from 4605 low-alloy This part is used to mount
steel, the three parts are the blade of an electric
made close to net shape, handheld keyhole saw. It
with only a few secondary connects the blade to the
operations performed to achieve close tolerances. The oscillating drive. The material is MIM-316L stainless steel at a
output shaft is a complex part with three small holes at density of 7.75g/cm³. Overall dimensions are 19mm x 12mm
120deg inter crossing each other, and thin wall thickness in x 9mm and the weight is 11.7g.
the cover part and close GD&T makes them good parts for Two gates are used in moulding to ensure a good filling of
MIM .As MIM is able to produce 3 parts of 5 part assembly the die. Tolerances on parallelism and the flatness of the
and make the supply chain lean, MIM is a sustainable process. slot surface are better than 0.05mm. This MIM part was
These 3 parts get assembled in the Dremel tool. This is previously made by investment casting, but the tolerances
called as “Quick Change Assembly” since one can change any were not good enough to ensure trouble-free functioning.
tool bit within seconds. The tool will run at 35000 rpm. MIM offers closer dimensional tolerances, a better surface
finish (Ra 3.2 µm) and a considerable cost reduction.
UNDERBARREL
Mimecrisa, Ecrimesa
Group, Spain
Designed for MIM with
know-how interchange
between Final User and
MIM maker.
Big saving in cost compared to if the part would be machined.
MIM design rules for uniform wall thickness were applied to
avoid deformation after sintering.
34
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Literature
Introduction to Powder Metallurgy The Process and its Products – 6th Edition, EPMA, 2008
'Powder Injection Molding - Design & Applications' by R. M German, Metal Powder Industries Federation, 2003
'Material Standards for Metal Injection Molded Parts', MPIF Standard # 35, 1993-942007 Edition, MPIF
Soft Magnetic Materials – Fundamentals for PM and Metal Injection Moulding – Monograph Lall, Chapman
'International Atlas of Powder Metallurgy Microstructures' by P. Beiss, K. Dalal, MPIF 2002
Mulser, M. and Petzoldt, F.: Standards for Metal Injection Moulding: Progress to-date and future challenges, PIM International,
Vol. 11, No. 1, March 2017, pp. 59-66.
Mulser, M.: Joining during shaping: Two-component MIM provides new possibilities, Metal Powder Report 71 (2016), 6, pp.
445-449, DOI: http://dx.doi.org/10.1016/j.mprp.2016.08.004.
Wieland, S. and Petzoldt, F.: Binder Jet 3D-Printing for Metal Additive Manufacturing: Applications and Innovative Approaches,
Ceramic forum international cfi, No. 10, 2016, pp. 26-30.
For information about this literature and much more visit www.epma.com
Acknowledgements
The original text for this brochure was prepared and edited by Dr Georg Schlieper (Consultant), Dr Gordon Dowson
(Consultant), Mr Bernard Williams (formerly Executive Director EPMA) and Prof Frank Petzoldt (Fraunhofer IFAM, Bremen)
For this revised version the EPMA gratefully acknowledges the assistance of:
Prof Frank Petzoldt (Fraunhofer IFAM Bremen)
Mr Keith Murray (Sandvik Osprey)
Mr Georg Breitenmoser (Parmaco)
Dr.-Ing. Marco Mulser (Fraunhofer IFAM Bremen)
Dipl.-Ing. Sandra Wieland (Fraunhofer IFAM Bremen)
The EPMA is indebted to the companies producing MIM parts for their cooperation in contributing the photographs and
Case Studies; also to the Metal Powder Industries Federation, Princeton, New Jersey, USA, and to the journal 'Metal Powder
Report', for their permission to include much useful information on design and property aspects of metal injection moulding.
The EPMA EuroMIM Group, which comprises the majority of European MIM parts producers, raw material and equipment
suppliers and research organisations developed the technical guidelines in this brochure as part of the EU funded
MIMNET project.
Lionel Aboussouan, Executive Director, EPMA – October 2017
Want to learn more about MIM?

Visit the website 'DesignforPM' at www.designforpm.net for a comprehensive online resource for designers and
engineers who are interested in learning more about PM including MIM.
You can also search our online EPMA MEMBERS’ DIRECTORY where you can find detailed product information.
For details go to www.epma.com/members-directory
R&D Club Projects

The EPMA is active in many types of project either as a partner or as project manager. These projects are
generally either 'club projects' which are financed by and restricted to a small number of members or
Government funded projects which tend to be larger and of longer duration.
In EPMA Club Projects a subject of importance to EPMA Members is identified (typically by an EPMA
Committee); a specification is prepared and quotations are obtained from specialist organisations or
experienced consultants; the most appropriate offer is then circulated to relevant EPMA members with an
invitation to participate in a consortium. Providing sufficient members express commitment, a Consortium
Agreement is normally drafted, agreed by the members, and the project commences.
For a list of current projects please visit www.epma.com/projects or if you would like more information
please contact Dr. Lionel Aboussouan, EPMA's Executive Director on la@epma.com
36
EPMA
POWDER
METALLURGY
CONGRESSES
European Powder Metallurgy Association organizes every year the Euro Powder Metallurgy
Congress & Exhibition.
Only once every six years, the Powder Metallurgy World Congress is held in Europe
and is an essential destination for the international PM community to meet its suppliers,
customers and research partners,as well asexploring the latest innovations in PM technology.
It attracts industry leaders, decision-makers, respected academics and PM related companies and
personnel from across the supply chain.
The programme of plenary, keynote, oral and poster presentations focus on all as-
pects of PM:
POWDER CONSOLIDATION TOOLS FOR

APPLICATIONS MATERIALS
PRODUCTION TECHNOLOGIES IMPROVING PM
congress.epma.com
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1 avenue du Général de Gaulle
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Epma Introduction To PM Mim

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european powder

AN EPMA SECTORAL GROUP

Process | Properties & Testing | MIM Design

European Metal Injection Moulding Group

EPMA Membership Benefits

Join EPMA at www.epma.com/membership

Introduction to Metal Injection Moulding (MIM)

Promoting Powder Metallurgy Technology

right angles to the pressing direction cannot be made

Metal Injection Moulding

2. RAW MATERIALS USED IN MIM

Promoting Powder Metallurgy Technology

2.1 Metal Powders

Stainless steels Refractory metals and hardmetals (cemented carbides).

Low alloy steels Copper alloys

a) Carbonyl Iron Powder Tool Steels and High Speed Titanium,

Comparison of Small Particle Production Techniques

Technique Size [µm] Shape Materials

The Ideal MIM Powder Characteristics are:

• Sufficient interparticle friction to avoid distortion after binder removal

2.2 Characterisation of MIM Powders

Fig. 2.2: Schematic of laser diffractometry

Fig. 2.3: Typical particle size distribution of a MIM

Binder Main Ingredients Polymer Backbone Additives

Gelatine Binders Water Methyl cellulose / Agar Glycerine / Boric acid

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2.5 Characterisation of MIM Feedstock

The test methods proposed here have been agreed by the

Fig. 2.4: Gas Atomizer, Courtesy of Sandvik Osprey

Fig. 2.5: Sample for shrinkage measurement, Courtesy of BASF

3.THE MIM PROCESS

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3.1 Injection Moulding

Fig. 3.3: Positioning of the parts is an

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4. PROPERTIES OF MIM PRODUCTS

4.1 Density and residual porosity

4.2 Mechanical Properties

37.6 0 R 7.5 ± 0.1

Fig. 4.1: Tensile test specimen according to ISO 2740

Promoting Powder Metallurgy Technology

Global Powder Metallurgy Property Database

Ultimate Tensile Strength v Elongation

Graph: Example of plotted chart from GPMD

4.3 Fatigue Strength

4.4 Heat Treatment

4.5 Corrosion Resistance

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Interrelation between Corrosion Resistance and Other Properties

Chromium content and chromium distribution

5. MIM DESIGN GUIDELINES

5.1 Part design

Holes and other internal geometries

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Transition from thick to thin, corners

Fig. 5.5: Surface steps should be

Reducing stress concentrations

Design of internal threads

5.2. Mould design

Mould parting lines

Ejector pin marks

Promoting Powder Metallurgy Technology