The core capability of Metal Injection Molding (MIM) is to make complex metal parts out of high-temperature alloys with good material properties, excellent repeatability, and reasonable cost. Here are the significant factors in deciding whether a component will benefit from MIM:
1. The material required has a relatively high melt temperature (>2000ºF), e.g. iron, nickel, cobalt, copper or tungsten-based alloys. If the properties of lower-melting alloys like zinc or aluminum are acceptable, then die casting is almost always a more economical approach.
2. The component design is too complex for processes like stamping, screw machining, fine blanking, cold heading or traditional powder metallurgy.
3. Component properties require performance (e.g. corrosion resistance, magnetic permeability, thermal expansion) similar to wrought alloys.
4. Thin sections & fine details are required which would be difficult to investment cast.
5. The geometry can be achieved using standard plastic injection molding tooling techniques, with secondary operations if necessary.
6. Good surface finish is required; MIM typically produces surface finishes better than 32 RMS.
7. Part cross-section thicknesses are < 8 mm & part weight is < 100 grams.