Metal Injection Molding

www.easea-intl.com

Company profile

Easea International Ltd. specializes in providing Metal Injection Molding (MIM) solutions in terms of design, manufacturing, sourcing and marketing to a wide variety of industries, such as defense industry, electronics, automotive, IT industry, hand power tools, consumer, and medicalinstruments, etc.

Established over ten years ago, Easea has been supplying millions of parts every year for the military and commercial customers. Our major product ranges are made from Fe-Ni alloy, stainless steel, heavy alloy and cemented carbide alloy. With our experienced technical staff, state-of-the-art manufacturing facilities and rich production experience, we are capable of supplying your orders whether in thousands or millions of pieces at a competitive price. Using MIM technology, we provide a simple solution for your complex parts.

Our manufacturing facilities are ISO 9001:2000 certified.

We are sincerely looking forward to establishing long-term business relationship with customers from all over the world.

Continuous type furnace, suitable for high volume production.

Batch type furnace suitable for pilot series or low volume applications.

Company profile

• Over ten years MIM production know-how.• Approved supplier for firearms manufacturers.• ISO 9001:2000 certified. • State-of-the-art manufacturing facilities.

• Manufacturing and testing/measuring equipment.

Company profile

• Product ranges: hand/power tools parts, firearms parts, automotive parts, mechanical/electronic parts, sewing machine fittings, printing machine components, stainless steel medical instrument components, watch and lock components, etc.

• Customers: Black & Decker, Bosch, SATA, firearmsmanufacturers, contract manufacturers, subcontractors, etc.

Company profile

MIM technology

• Metal Injection Molding(MIM) is an advanced technology. It offers myriad tangible advantages over other manufacturing processes. In fact, where small part size, part complexity, and high volumeare primary factors, this sophisticated, time-saving, and cost-effective technology is often the optimal solution.

• Using extremely fine metal powders, MIM technology produces parts in high-density and near net-shape with the properties approaching that of wrought material.

• Ferro-nickel alloy, stainless steel, carbide alloy, and other non-ferrous alloys such as titanium, are common materials for MIM.

Mounting support: Ferrite alloy; 0.05g; 1 million pieces per year.

• More significant, the MIM process allows engineers more latitudewhen designing a component, no longer constrained by the parameters of cost, size, or shape. The value of removing these restrictions from the engineer's thought process cannot be overstated.

• MIM will find more application opportunities from the freedom ofdesigning.

MIM technology

• MIM Process

Binder

Mixing

Molding

Debinding

Sintering

Postprocessing

Moldmaking

Metalpowder

Mold Making

Molds similar to those used in conventional plastic injection molding are designed and fabricated. CAD/CAM technology is used to enhance the design and fabrication process.

Mixing

Fine metal powders, thermoplastic binders and other proprietary materials are mixed to form a homogeneous feedstock.

Molding

Conventional injection molding machines are used to create “green parts.” These parts are typically 15-20% larger than the finished product.

Debinding

Green parts are exposed to heat, solvent or a combination of both to remove most of the binder material. The de-bound are called “brown parts”.

Sintering

“Brown parts” are sintered in vacuum-type furnaces. The intense heat shrinks the parts 17-22% to almost complete density, however the shrinkage has already been taken into consideration when the molds are designed. The parts are then complete. Also, secondary machining or surface treatment is available.

MIM technology

• MIM Advantages

MIM applications are ideally suited for components that are relatively complex, very small, and will be produced in large quantities, at the same time requiring high strength, high performance and cost efficiency.

Comparison between MIM & Other Processes

MIM technology

Very HighVery HighPoorVery GoodVery Good100%Quite Many0.5mmHighMachining

MediumMediumMediumPoorRa 5μm100%Medium2mmMediumInvestment Casting

Very LowLowMediumMediumMedium100%Very Few0.8mmHighDie Casting

LowHighVery GoodGoodMedium<95%Many1mmLowP/M

MediumVery LowVery GoodGoodRa 4μm95~99%Many0.5mmVery HighMIM

Simple Part Cost

Complex Part Cost

High Volume

Capability

Tolerance Capability

FinishDensityMaterial Selection

Min.WallThickness

ComplexityProcess

• MIM Advantages

Comparison between MIM & Other Processes

MIM technology

• MIM Part Selection Criteria

• Size: From 0.1 grams to over 150 grams in weight. A volume of, or less than, a golf ball or deck of playing cards.

• Complexity: Typically if a part has more than 25 measurable dimensions it will make a good candidate for MIM.

• Quantity: The quantity of parts plays a major role in the cost effectiveness of MIM. 10,000 pieces per year is as a minimum in most cases.

• Tolerances: ±0.03 ~ ±0.05mm per cm.

These are sound guidelines, yet not the absolute criteria. Thereare some fairly large parts or parts in low quantities produced by MIM, simply because they are just too costly to produce using traditional methods.

MIM technology

• MIM Materials

Properties of Typical MIM Materials

MIM technology

17.8320Hv1WHATungsten Heavy Alloy

7.965 HRC 8001200M2High Speed Steel

4.24827923TI-6AI-4V (AGED)

4.210716744Ti-6AI-4V (ANNEALED) Titanium

8.3Cu 100% Copper Based

7.758 HRB 33158448Alloy 50 Materials

7.568 HRB 20262427Fe-SiSoft Magnetic

Stainless Steel

7.593 HRB 27516620ASTM A276 (2205) Duplex Structure

7.636 HRC 71102124017-4 PH H900 Stainless Steel

7.625 HRC 1264082717-4 as Sintered Precipitation Hardening

7.559 HRC 413431584AISI 440C (Premium)

7.652 HRC 816531929AISI 420 (Premium) Stainless Steel

7.350 HRC 1033AISI 420 Martensitic

Stainless Steel

7.565 HRB 30241413AISI 430 Ferritic SS

7.7AISI 304L Stainless Steels

7.765 HRB 30172482AISI 316L Austenitic

7.548 HRC 414461653MIM 4605 heat treated

7.590 HRB 15482689MIM 4605 as sintered

7.660 HRB 262554138% Ni-Steel Low Alloy Steels

Density g/cm3Hardness Elong.% YS (0.2%)

MPaUTS MPaAlloy Name Material Group

• MIM Materials

MIM Material Chemstries

MIM technology

W balance0.5-12.5-3.5WHATungsten Heavy alloys

6% W, 2% Vbalance0.3 max4.5-5.53.5-4.50.8-1.1 M2High Speed steel

6% AI,4% V, Balance Ti Ti-6AI-4V Titanium

99 nom Cu-100% Copper Based

balance 50 nom 0.1 max Alloy 50 Materials

balance 2-30.1 max FeSiSoft Magnetic

Stainless Steel

P 0.03 max,S 0.02 max balance 1 max 2.5-3.5 4.5-6.5 21-23 0.03 max ASTM A276 (2205)

Duplex Structure

Stainless Steel

Hardening

P 0.04 max,S 0.03 max balance 1 max 3-53-515.5-17.5 0.07 max 17-4 PH Precipitation

P 0.04 max,S 0.03 max balance 1 max 16-18 0.95-1.20 AISI 440C Stainless Steel

P 0.04 max,S 0.03 max balance 1 max 12-140.15 min AISI 420 Martensitic

Stainless Steel

P 0.04 max,S 0.03 max balance 1 max 16-18 0.12 max AISI 430 Ferritic

P O.045 max,S 0.03 max balance 1 max 8-1218-20 0.03 max AISI 304L Stainless Steels

P O.045 max,S 0.03 max balance 1 max 2-310-1416-18 0.03 max AISI 316L Austenitic

balance 0.5 max0.5 max 1.5-2.5 0.6 max* MIM 46XX* Steels

balance 0.5 max0.5 max 6.5-8.5 0.6 max* 8% Ni-Steel Low Alloy

Other wt% Fewt%

Siwt%

Cuwt%

Mowt%

Ni wt%

Cr wt%

C wt% Alloy nameMaterial Group

* Carbon levels are variable with application

• MIM Applications

• Automotive: airbag firing pins, power window system, safety belts, jacking systems of auto doors, small gears, auto AC systems, turbo fans, racks of braking systems, and sensors of fuel systems.

• Firearms: small arms parts, armour-piercing bullet core, fuzes.

• IT industry: typewriters, hard disc drive parts, magnetic cores, axle pins, and porcelain plugs of fiber optical communications.

• Tools: drill bits, clamps, nozzles, thread milling cutters, pneumatic tools, power tools and fishing gears.

• Medical instrument: orthodontics brackets, laparoscopic parts like graspers, dissectors, tweezers and instrument handles.

• Electronics: Mini motors, connecters, mobile phone hinges, keys and sensors

• Other applications: watchcases, watch chains, electric toothbrushes, scissors, golf heads, jewelry pendant and links, cutting tools and locks.

MIM technology

Application examples

Application examples

Application examples

Application examples

Application examples

Metal Injection Molding

EASEA INTERNATIONAL LIMITEDRm.5-503, 20#, No.618, Qingshan Road, Qingdao, Shandong, China

Tel: +86 532 8763 2945 Fax: +86 532 8763 2945www.easea-intl.com marketing@easea-intl.com