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What Is Metal Injection Molding? Why Manufacturers Trust It

Tue, 07 Apr 2026 17:42:51 GMT

Modern manufacturing demands precision, efficiency, and consistent results. As industries continue to evolve, manufacturers are turning to advanced production methods that deliver complex metal components with tight tolerances. One process gaining widespread attention is metal injection molding , a technology that combines the versatility of plastic injection molding with the strength of powdered metallurgy. This process allows manufacturers to produce highly detailed metal components at scale while maintaining cost efficiency and superior quality.

Chicago’s diverse industrial sector relies on precision parts for everything from medical devices to automotive systems. As a result, many manufacturers are adopting this advanced technique to meet growing production demands and maintain competitive advantages.

Understanding the Basics of Metal Injection Molding

Metal Injection Molding, often referred to as MIM, is a manufacturing process designed to create complex metal components with high precision.

How the Process Works

The process combines powdered metal with a binder material to create a feedstock that can be molded into intricate shapes.

The basic stages include:

Feedstock preparation: Fine metal powders are mixed with polymer binders to create a moldable material.
Injection molding: The material is injected into molds, like plastic injection molding.
Debinding: The binder is carefully removed from the molded part.
Sintering: The part is heated at high temperatures to fuse the metal particles together, creating a dense and durable metal component.

Manufacturers using metal injection molding benefit from the ability to produce detailed parts that would otherwise require extensive machining or assembly.

What Types of Parts Are Produced With Metal Injection Molding?

One of the major advantages of MIM technology is its ability to produce small, complex metal parts with tight tolerances.

Common Components Produced Through MIM

This process is ideal for parts that require precision and repeatability, such as:

Medical device components.
Automotive system parts.
Aerospace fittings.
Industrial equipment components.
Electronic hardware pieces.

Because metal injection molding in Chicago, IL, allows for complex geometries and smooth finishes, manufacturers can reduce secondary machining operations and improve production efficiency.

Industries in Chicago That Depend on Metal Injection Molding

Chicago is home to a wide range of industries that require reliable metal component manufacturing.

Medical Device Manufacturing

Medical manufacturers rely on extremely precise components to meet strict safety and regulatory standards.

Examples of MIM medical components include:

Surgical instruments.
Orthopedic hardware.
Dental equipment parts.
Medical device housings.

Using metal injection molding ensures these parts meet the strict dimensional accuracy and material consistency required in healthcare applications.

Automotive Manufacturing

The automotive industry demands durable, high-performance parts that can be produced at scale.

Common MIM automotive components include:

Transmission parts.
Fuel system components.
Lock mechanisms.
Structural fasteners.

This manufacturing approach allows automotive suppliers to achieve the strength of traditional metal parts while benefiting from efficient production.

Aerospace and Industrial Applications

Aerospace and industrial manufacturers require components that perform reliably under extreme conditions.

Examples include:

Aircraft hardware.
Control system components.
High-strength brackets.
Mechanical system connectors.

Manufacturers across these sectors rely on metal injection molding in Chicago, IL, to create components that meet rigorous engineering specifications.

Why Manufacturers Choose Metal Injection Molding

There are several reasons why manufacturers continue to adopt this technology as part of their production strategies.

Consistency and Precision

Metal injection molding allows manufacturers to produce parts with extremely tight tolerances. The molding process ensures that each component matches the original design specifications.

Key benefits include the following:

Uniform part quality.
Reduced dimensional variation.
Excellent surface finishes.
High repeatability across production runs.

These qualities make metal injection molding in Chicago, IL, particularly attractive for industries that require precise mechanical performance.

Cost Efficiency for Large Production Runs

Another major advantage of MIM is its cost-effectiveness when producing high volumes of complex parts.

Manufacturers benefit from:

Reduced material waste.
Lower machining costs.
Faster production cycles.
Fewer secondary operations.

Over time, these efficiencies significantly reduce production costs while maintaining product quality.

The Importance of Quality Control in Metal Injection Molding

Precision manufacturing requires strict quality control processes to ensure every component meets required specifications.

Key Quality Standards in MIM Manufacturing

Leading manufacturers follow comprehensive inspection and testing procedures, including:

Material verification.
Dimensional inspection.
Density and structural testing.
Surface quality evaluation.

Companies such as Smith Metal Products Inc. emphasize rigorous quality control to ensure components meet both engineering requirements and industry standards.

These procedures help ensure that metal injection molding in Chicago, IL, delivers consistent and reliable results for demanding applications.

Scalability for Growing Manufacturing Demands

As production needs increase, manufacturers must rely on processes that can scale efficiently without sacrificing quality.

Metal injection molding offers several advantages for expanding production.

Scalability Benefits

Manufacturers can increase output while maintaining consistency through:

Automated injection molding systems.
Repeatable tooling processes.
Efficient batch production.
Reduced manual labor requirements.

Because of these benefits, many companies rely on metal injection molding in Chicago, IL, as a long-term solution for high-volume component production.

Why Precision Manufacturing Matters in Today’s Industrial Market

Precision components play a critical role in the performance of modern machinery, vehicles, and medical equipment. Even small dimensional errors can affect functionality, reliability, or safety.

By combining advanced molding techniques with strict quality standards, manufacturers can produce durable metal components that meet exact design specifications. This approach improves reliability, reduces product defects, and supports innovation across multiple industries.

Contact Smith Metal Products for precision manufacturing solutions

Manufacturers searching for reliable production solutions can benefit from expert support and advanced technology. Smith Metal Products provides professional metal injection molding in Chicago, IL, delivering precision metal components with tight tolerances and consistent quality for a wide range of industries.

From complex small parts to scalable production runs, their experienced team is committed to meeting the demanding standards of modern manufacturing. For companies seeking dependable results and efficient production methods, now is the time to explore professional MIM solutions. To learn more or request a consultation, call (651) 257-3143 and speak with the team at Smith Metal Products about your precision manufacturing needs.

Why Professional Metal Fabrication and Installation Matters

Fri, 30 Jan 2026 18:45:13 GMT

When it comes to metal fabrication in Washington, DC, companies and property owners alike must prioritize quality and expertise. Whether embarking on a commercial or industrial construction project, ensuring the metal components are fabricated and installed by seasoned professionals is critical to a successful outcome. Smith Metal Products, a trusted name serving Washington, DC, serves as a reliable example of what skilled craftsmanship and precise installation can achieve. This article delves into why professional metal fabrication is vital, highlighting structural integrity, safety compliance, and the nuances of local codes and permitting processes that only expert fabricators understand.

The Importance of Choosing Experts for Metal Fabrication

Metal fabrication is not merely about shaping metal; it’s about creating components that will withstand the test of time and usage, especially in commercial and industrial settings. Choosing professional metal fabrication guarantees that experienced fabricators apply the best practices, advanced technologies, and high-quality materials. Expertise in metal fabrication ensures that all dimensions, welds, and finishes meet exacting standards, preventing costly mistakes and future repairs.

Commercial and industrial projects involve complex metal structures, such as beams, frames, staircases, and railings, where precision is non-negotiable. Without expert fabrication and installation, poor fits or weak joints can compromise the whole structure’s integrity, leading to safety risks and potential legal liabilities.

How Professional Installation Ensures Structural Integrity and Safety Compliance

Professional installation is just as critical as fabrication. When metal components are expertly installed, they uphold the structural design’s integrity and function as intended under load and stress. Washington, DC, projects demand adherence to rigorous safety standards, which only professionals with thorough knowledge of local building codes can ensure.

Safety compliance involves meeting national standards like OSHA regulations as well as local codes specific to DC. Proper installation of fabricated metal components reduces the risk of accidents like structural failure, falls, or fire hazards. Moreover, professional installers identify site-specific challenges early on, such as load distribution issues or environmental impacts, adapting their approach accordingly.

Long-Term Durability Through Skilled Fabrication and Installation

Durability in metal fabrication means resistance to wear, corrosion, and external stress over an extended period. Professional fabricators use certified materials and precise finishing techniques such as galvanizing or powder coating, which enhance longevity. Coupled with expert installation, these elements prevent premature deterioration and maintain performance.

Washington, DC’s climate, with its humidity and seasonal temperature shifts, can accelerate metal corrosion if not properly treated. Professional metal fabrication accounts for these factors and applies industry best practices to maximize the lifespan of metal structures, reducing maintenance frequency and overall costs.

The Cost Benefits of Professional Metal Fabrication and Installation

Investing in professional metal fabrication might seem like a higher upfront cost, but it offers significant long-term financial benefits that far outweigh initial expenses. Proper fabrication and installation reduce the likelihood of costly repairs, replacements, or project delays caused by errors or material defects. Experienced fabricators optimize material usage, minimizing waste and managing resources efficiently, which helps control project budgets.

Moreover, professional metal fabricators are well-versed in efficient project timelines, meaning commercial and industrial projects can avoid extended downtime or interruptions. This timely completion translates to savings in labor costs and allows businesses to start using their facilities sooner.

By ensuring compliance with stringent Washington, DC building codes and safety regulations, professional metal fabrication services also help avoid expensive fines or legal complications. In essence, partnering with seasoned fabricators safeguards your investment and supports a smoother, more cost-effective project lifecycle.

Navigating Building Codes, Permits, and DC-Specific Challenges

Washington has particular building codes and permitting processes that must be respected in metal fabrication projects. Professionals bring experience navigating these local regulations, ensuring that all metal works pass inspections and are legally compliant. This expertise avoids costly delays or reworks due to failed inspections or noncompliance.

Projects in Washington, DC, also face unique challenges, such as historic district restrictions or environmental requirements, that influence metal design and installation choices. Skilled fabricators work closely with architects, engineers, and regulatory bodies to craft solutions that meet aesthetic, environmental, and legal needs simultaneously.

Smith Metal Products: Experience You Can Rely On

Smith Metal Products exemplifies the value of experience and professionalism in metal fabrication in Washington, DC. Their expertise spans a wide range of custom fabrication services paired with precision installation, making them a trusted partner for complex commercial and industrial projects. Their team’s in-depth knowledge of local codes and regulations supports projects’ smooth completion while upholding the highest quality standards.

Secure Quality and Precision

Choosing professional metal fabrication in Washington, DC, goes beyond aesthetics; it’s an investment in safety, durability, and legal peace of mind. For projects that demand expert craftsmanship and adherence to local standards, partnering with experienced fabricators ensures success from start to finish. If you’re planning a custom metal fabrication project in Washington, DC, contact Smith Metal Products today for a consultation and experience firsthand the benefits of professional service tailored to your exact needs.

Manufacturers & Metal Injection Molding for Precision Parts

Fri, 03 Oct 2025 02:23:20 GMT

San Francisco, CA, renowned for its thriving technology and innovation ecosystem, has witnessed a surge in demand for highly sophisticated micro-precision components. Producing these parts using traditional methods presents numerous challenges, especially given the high operational costs associated with manufacturing in the Bay Area. Increasingly, local manufacturers are seeking transformative solutions, and metal injection molding provided in San Francisco, CA, is at the forefront. Smith Metal Products offers this efficient, scalable method, which is redefining the region's approach to precision manufacturing, delivering exceptional results for industries ranging from electronics to aerospace, defense, and IoT.

The Traditional Precision Parts Manufacturing Challenge

The quest for micro-precision parts is nothing new in San Francisco, CA’s dynamic industrial landscape. Traditional manufacturing techniques—such as CNC machining, investment casting, and stamping—often fall short when tasked with producing extremely intricate, small-scale geometries. These methods can result in high material waste, extensive labor requirements, long lead times, and fluctuating quality. In regions like San Francisco, CA, where facility rents, skilled labor, and material costs are significantly higher than the national average, these problems are magnified.

For companies developing the next generation of electronics, sensors, or medical devices, even the smallest defects or inconsistencies can render entire batches unusable, jeopardizing product launches and bottom lines. This pressure is especially acute for startups and high-growth enterprises based in the Bay Area that are looking for efficient ways to move to mass production without sacrificing quality or cost control. It has become abundantly clear that a new approach is necessary—one that mitigates the inherent drawbacks of legacy manufacturing methods.

This is where metal injection molding steps in as a game-changer, offering San Francisco, CA, manufacturers a way to overcome traditional limitations and seize new opportunities in precision parts manufacturing.

What Is Metal Injection Molding?

Metal injection molding—or MIM—is an advanced manufacturing process that blends traditional powder metallurgy with plastic injection molding technology. The process involves mixing fine metal powders with a binder to create a feedstock, which is then injected into a mold cavity under high pressure. After forming, the binders are carefully removed, and the parts undergo sintering, resulting in dense, high-strength metal components with exceptional precision.

Unlike conventional manufacturing processes that require cutting, machining, or stamping parts from blocks of metal, metal injection molding allows manufacturers in San Francisco, CA, to create intricate designs in a single molding cycle. This is especially advantageous in applications where complexity, tight tolerances, and repeatability are critical. Electronics, aerospace, defense, and IoT companies in the Bay Area increasingly rely on MIM for their most demanding projects.

Overcoming High-Cost Regional Barriers With MIM

One of the biggest advantages of metal injection molding is its ability to address the high operational costs endemic to San Francisco, CA. Real estate prices, labor rates, and utility costs are all major concerns for manufacturers. With traditional manufacturing approaches, each additional process—be it cutting, finishing, or assembly—translates to higher costs.

Metal injection molding provides a streamlined solution. By consolidating multiple manufacturing steps into a single operation, it drastically reduces labor requirements and production time. It also minimizes material usage, as parts are formed to near-net shape, reducing scrap and post-processing expenses. The result? Lower unit costs, reduced waste, and faster turnaround, making MIM a cost-effective choice for precision parts manufacturing in even high-cost markets like San Francisco, CA.

This efficiency empowers startups, small businesses, and established corporations alike, enhancing their competitiveness without forcing them to sacrifice quality or scale.

The Benefits of Metal Injection Molding for Manufacturers

San Francisco, CA’s market for micro-precision parts is bustling, yet challenging. Here’s how metal injection molding is delivering value:

Tighter Tolerances

Metal injection molding offers unparalleled control over part dimensions, enabling manufacturers to achieve extremely tight tolerances—down to microns. This is paramount for applications in electronics, medical devices, aerospace, and defense, where precision directly impacts performance and safety.

Lower Waste

Unlike subtractive manufacturing processes that start with a metal billet and machine away excess material, MIM produces parts to near-net shape. The minimal waste generated not only contributes to cost savings but also supports sustainability goals—a major focus for many San Francisco, CA, companies.

Excellent Surface Finish

With MIM, surface finish quality is consistently high, often eliminating the need for secondary finishing operations. This is particularly beneficial for aesthetic or functional components used in consumer electronics, IoT devices, and luxury goods produced in San Francisco, CA.

Scalability and Mass Production

One of the defining strengths of metal injection molding is its scalability. Once the initial mold and feedstock formulation are developed, manufacturers can produce thousands—even millions—of identical parts with speed and repeatability. This mass production capability is a boon for companies in the Bay Area with ambitious growth plans, facilitating rapid market entry and expansion.

Industries Benefiting From Metal Injection Molding in San Francisco, CA

MIM’s versatility means it is particularly well-suited to the needs of the Bay Area’s diverse industries:

Electronics: Micro connectivity devices, sensor housings, and shielding components benefit from MIM’s precision and cost efficiency.
Aerospace: The ability to produce strong, lightweight, complex geometries supports innovation in aircraft and satellite manufacturing.
Defense: High-reliability weapon components, structural elements, and sensing devices require MIM’s tight tolerances and strength.
IoT and Tech Startups: Compact form factors and high-volume scalability power the next wave of smart devices and connected technologies.

San Francisco, CA’s unique economy—where speed, quality, and lean operations are essential—makes metal injection molding a strategic tool for product designers and engineers.

The MIM Process: Full Production

One of the most empowering attributes of metal injection molding is its adaptability across the product development cycle. In San Francisco, CA, innovative companies use MIM for everything from mass production. The process is as follows:

1. Design & Tooling: Engineers create CAD designs to capture even the most complex details. Molds are then precision-fabricated.
2. Feedstock Preparation: Metal powders are blended with binders to obtain optimal flow during injection.
3. Injection Molding: The feedstock is injected into the mold, replicating intricate features with consistency.
4. Debinding & Sintering: Binders are chemically or thermally removed, and parts are sintered to achieve their final density and mechanical strength.
5. Secondary Operations (Optional): Parts are optionally finished, coated, or assembled, often requiring minimal post-processing.

This iterative, scalab le process means San Francisco, CA, manufacturers can quickly respond to market demands, customer feedback, and evolving technologies.

Why MIM Is the Future of Precision Manufacturing in San Francisco, CA

The Bay Area’s manufacturers face constant pressure to innovate, scale efficiently, and deliver flawless products. Metal injection molding provides San Francisco, CA , businesses with a powerful solution, overcoming the limitations and high costs of traditional manufacturing. Whether creating complex aerospace components, micro connectors for electronics, or robust IoT device housings, MIM offers unmatched advantages: tighter tolerances, reduced waste, exceptional surface finish, and mass production capability.

With local expertise and global reach, metal injection molding will play a pivotal role in helping San Francisco maintain its status as a world leader in technology and advanced manufacturing.

Harness the Power of Metal Injection Molding Today!

Manufacturers—if you’re ready to elevate your precision parts production with metal injection molding provided in San Francisco, CA, now is the time! Whether you’re in electronics, aerospace, defense, or the fast-growing IoT industry, our team is ready to guide you through every step of the process. Contact us today to discuss your project needs and discover how MIM can unlock new levels of efficiency and quality for your business.

Metal Injection Molding Medical: Transforming the Industry

Thu, 25 Sep 2025 16:08:19 GMT

If you’re exploring innovative ways to produce high-quality medical components, metal injection molding medical in Boston, MA, offers unprecedented advantages that are reshaping the healthcare industry. Smith Metal Products is at the forefront of delivering precision metal injection molding solutions for medical device manufacturers, enabling complex geometries, superior material strength, and miniaturized parts that meet the rigorous demands of modern medicine. This blog will dive into how the metal injection molding medical process is transforming medical technology development, especially in this thriving biotech hub.methods.

What Is Metal Injection Molding, and Why Is It Ideal for Medical Applications?

Metal injection molding (MIM) is a manufacturing process that combines fine metal powders with a binder material to create a feedstock, which is then injected into a mold cavity. Once shaped, the component undergoes debinding and sintering to achieve the desired density and strength. This process enables the production of highly complex shapes and precise small parts that traditional manufacturing struggles to achieve efficiently.

In medical applications, the benefits are substantial. Metal injection molding medical technology is particularly suited for creating miniaturized, intricate, and durable components that are indispensable in surgical instruments, orthodontic devices, and drug delivery systems. MIM parts exhibit excellent material strength, corrosion resistance, and biocompatibility—critical factors for any medical-grade component. This ability to combine complexity with robust material properties makes MIM a game-changer in medical device manufacturing.

Why Boston Is a Growing Hub for the Metal Injection Molding Medical Industry

Boston, MA, is renowned worldwide as a medical and biotech powerhouse. The city’s numerous research institutions, hospitals, and cutting-edge companies fuel an ongoing demand for innovative medical components and devices. With this surge in innovation, metal injection molding medical technology in Boston, MA, is increasingly sought after as a method to meet the high-volume, high-precision needs of local manufacturers. This growing reliance on advanced manufacturing techniques underscores Boston’s commitment to pioneering medical advancements.

Boston’s medical device manufacturers require solutions that offer repeatable accuracy and cost efficiency without compromising quality. The precision and scalability offered by the metal injection molding medical process provide a competitive advantage, enabling local companies to bring new medical technologies to market faster. This environment of innovation and quality demand makes Boston an ideal location for advanced MIM services.

How Smith Metal Products Is Leading Metal Injection Molding Medical Technology in Boston, MA

Smith Metal Products has become a trusted partner for medical device manufacturers across Boston by harnessing the capabilities of the metal injection molding medical process in Boston, MA. Their expertise allows them to produce complex surgical instruments, orthodontic components, and intricate drug delivery system parts with unparalleled precision.

For example, surgical instrument designers often face challenges in achieving intricate shapes with lightweight materials that maintain strength and durability. Smith Metal Products uses metal injection molding medical techniques to manufacture these components cost-effectively while ensuring compliance with strict medical standards.

Orthodontic components, which demand biocompatibility and precise fit, also benefit substantially from Smith Metal Products’ MIM solutions. The company’s mastery of molding tiny, complex geometries ensures devices that improve patient outcomes and procedural efficiency.

Additionally, drug delivery systems require miniature parts that perform reliably without failure. Through metal injection molding medical techniques, Smith Metal Products delivers these sophisticated components consistently and at scale, helping innovators push the boundaries of pharmaceutical technology.

The Future of Medical Manufacturing With Metal Injection Molding Medical Techniques

As medical technologies continue to evolve, the demand for parts that combine complexity, performance, and affordability will only increase. MIM in the medical industry stands out as an indispensable manufacturing method capable of delivering on these needs. Boston’s status as a medical innovation hub will continue to drive growth and investment in precision molding technologies, reinforcing Smith Metal Products’ role as a leading provider. This momentum is expected to foster collaborations and innovations that further enhance medical manufacturing capabilities in the region.

Medical device manufacturers looking to capitalize on the next generation of tooling and components should consider metal injection molding medical technology as a primary solution. By leveraging this technology, companies can optimize product performance, reduce lead times, and scale production with confidence. The precision and reliability MIM offers will be crucial in meeting stricter medical regulations and increasing patient safety standards. Embracing metal injection molding medical in Boston, MA, empowers manufacturers to stay competitive in a fast-moving market and bring revolutionary healthcare solutions to life.

Transform Your Medical Device Manufacturing With Metal Injection Molding Medical Technology

If your business requires advanced medical components manufactured with pinpoint precision and durability, metal injection molding medical technology offers powerful advantages. Smith Metal Products is ready to help your company unlock these benefits. Contact Smith Metal Products today to discover how their expert metal injection molding medical services can transform your medical device manufacturing process and help you stay at the forefront of innovation. Don’t let manufacturing limitations hold your medical innovations back—embrace the future with metal injection molding medical in Boston, MA.

Expert Metal Injection Molding Medical in Boston, MA

Tue, 24 Jun 2025 06:56:35 GMT

Boston, Massachusetts, is a hub of medical innovation, where top-tier hospitals, research institutions, and biotech companies converge. As the demand for precision, biocompatibility, and complex medical device components continues to grow, metal injection molding medical in Boston, MA , is becoming the go-to solution for engineers and manufacturers. This advanced manufacturing technique allows for the creation of highly intricate metal parts that meet stringent medical requirements at a lower cost and with higher efficiency than traditional methods.

Why Boston’s Medical Manufacturers Are Turning to MIM

From Cambridge to the Seaport District, Boston is filled with companies pushing the boundaries of biomedical technology. These innovators require components that are not only precise but also cost-effective and scalable. That’s where metal injection molding medical in Boston, MA, excels. Traditional machining methods often fall short when it comes to miniaturization and complexity. MIM offers a clear advantage, producing parts with excellent surface finishes and mechanical properties, all while reducing material waste and post-processing time. For OEMs and device startups alike, this means lower costs, and higher consistency.

Why Metal Injection Molding Is the Smart Choice

Metal injection molding medical in Boston, MA , delivers unmatched benefits compared to traditional machining or casting. It offers:

Extreme Precision : Ideal for intricate, compact medical components.
Cost-Efficiency at Scale : Perfect for mass production.
Material Versatility : Including stainless steel, titanium, and more.

For manufacturers in Boston, this means faster production cycles, lower costs, and enhanced design freedom without sacrificing the strength or integrity required in medical applications.

The Future of Medical Manufacturing Starts in Boston

Boston’s status as a global medical and biotech capital makes it the perfect breeding ground for cutting-edge manufacturing solutions. With its concentration of world-renowned hospitals, research institutions like MIT and Harvard, and a thriving startup ecosystem, the city fosters innovation at every level of the healthcare industry. Among the most disruptive technologies rising in this space is medical metal injection molding in Boston, MA. This advanced process merges the design freedom of plastic injection molding with the strength and functionality of metal, allowing for the creation of high-precision components that meet the rigorous standards of today’s medical devices.

If your company is in the Boston area and ready to take advantage of the latest in precision manufacturing, metal injection molding medical in Boston, MA, is your best solution. Contact to learn how their MIM solutions can elevate your products and performance. Unlock the future of medical device innovation today!

Metal Injection Molding Compatibility

Mon, 31 Mar 2025 16:34:23 GMT

Metal Injection molding (MIM) Compatibility

How do you know if your part is a good candidate for metal injection molding (MIM)?

The first thing to think about is the quantity of parts you need. At Smith Metal Products, we work with customers looking for more than 25,000 parts per year if they have one design. For multiple designs, we look for over 10,000 parts per year for each design. Small runs of parts do not make sense for MIM with the cost of the molds needed for the process.

The second determination depends on the material used to make the part. The typical metals we use at Smith Metal Products include stainless steel and titanium. However, there are many other alloys that we have experience with and others that we would be willing to develop depending on the scope of your project. We cannot use aluminum, zinc, magnesium, or brass.

Part size can also dictate the compatibility with MIM. We look for maximum part lengths of three inches or less. However, there are some exceptions.

Wall thickness (or thin-ness) may have an impact on MIM viability. The minimum wall thickness that we look for is .020" or 5 mm. We also do not want walls that are thicker than .125" or 3mm. In some cases, we may be able to "core out" these areas in the design for manufacturability process.

Part weight is another consideration. Most of the parts we manufacture are under 25 grams, but we use 100 grams as the highest weight compatible with MIM.

Why does it make sense to use MIM? If you have higher priced machined or cast components, MIM may be a cost savings. If you are a machine shop, MIM can be used to create blanks and free up machine time for you to work on other projects. Some multi-component assemblies may be combined into a single MIM component.

Components made out of expensive materials like Inconel or titanium are good candidates since you do not cut away value material in the MIM process. The metal needed for the part is injected, not cut away from bar stock.

If you are considering a part for MIM, please email us at DFM@smithmetals.com and we will evaluate the part.

Quality - What is it?

Thu, 27 Mar 2025 20:59:12 GMT

Quality - What is it?

When you think about quality, what comes to mind?

Meeting tolerances? Consistency? Free of defects? Strong, stable complex parts?

All of these things come into play. Quality is important to us at Smith Metal Products. We want our customers to be glad they are working with us each and every time they place an order.

We strive to meet or exceed all of our customers' requirements every day.

Made only in the USA

Mon, 24 Mar 2025 19:05:14 GMT

Made only in the usa!

Smith Metal Products manufactures only in the United States. Located in Center City, Minnesota, Smith Metal Products in centrally located.

Why is it beneficial to work with a company producing products only in America?

1. You support American jobs and local communities.

2. You reduce shipping times from your metal injection molding supplier.

3. Your parts won't get stuck and delayed in customs.

4. You can speak with the people that work right where your parts are being made and collaborate on design for manufacturability.

5. You don't have to worry about the uncertainty of tariffs, because you are not importing your parts.

Some companies say they are manufacturing parts in their United States locations, and then have the designs made abroad.

Rest assured that if you work with Smith Metal Products, your parts are being manufactured in Minnesota.

If you would like to move your small, complex, high volume, metal part manufacturing back to the United States, email us at DFM@smithmetals.com

New Video Content Coming Soon!

Fri, 28 Feb 2025 17:14:32 GMT

New Video content coming soon from perkins media!

Last week on Tuesday, Perkins Media visited Smith Metal Products in Center City, Minnesota. They spent the day capturing what we do at Smith Metal Products, why our employees want to be here, and why customers like working with Smith. It is difficult to capture everything you want to say in a short video, but we are excited to see the end result.

The video will be used on our website as well as in our tradeshow booths. Here are some things we are looking to communicate through the video:

1. We value our customers and work hard every day to make high-quality products.

2. Since we are employee-owned, employees have an ownership mentality that translates to deeply caring about the products and service we provide.

3. Smith Metal Products takes care of our employees, and they are able to grow wealth for retirement through the ESOP (employee stock ownership plan).

4. We make everything in the USA. By working with us, customers are supporting American jobs. In addition, customers do not have to worry about long overseas lead times, higher shipping costs, uncertain tariffs, and parts getting delayed in customs.

5. Collaboration is important to us. We like to be involved in the product development process early to provide feedback on design for manufacturing. We can describe how different features will affect the metal injection molding process and ways we may be able to save the customer money by removing the need for some secondary machining operations.

6. We are a metal injection molding (MIM) company. Not every part is a good fit for MIM. If we think that a potential customer's part design could be made better in a different way (due to wall thickness, lack of complexity, low volumes, etc.), we will be honest and communicate that. We want our customer to be happy and confident in the choice to work with us.

Looking at the list above, we might need a couple videos, but we are excited for some fresh content.

We are here and ready to collaborate! If you have a design that might be a good fit for MIM, email us at DFM@smithmetals.com

Do you need video content for your business? Find out more about Perkins Media at www.perkinsmediagroup.com or email them at info@perkinsmediagroup.com

January and February Tradeshows

Tue, 25 Feb 2025 21:15:28 GMT

January and February 2025 tradeshows

January and February were busy months for us. First, we attended the SHOT Show® in Las Vegas, Nevada at the end of January. There was a lot to see, and so many people to talk to with 14.1 miles of aisles within the two convention centers! That is a lot of ground to cover. Companies bring their newest products for all to view and connect with fellow companies in the shooting, hunting, and outdoor recreation space. The Smith Metal Products team was able to connect with current customers and discover potential customers as well.

At the beginning of February, we traveled to Anaheim, California for MD&M West. This show was previously known as Informa Markets Engineering West. Under the name MD&M West, it now combines MD&M West, ATX West, D&M West, Plastec West, and WestPack. There are all types of manufacturers included in the 1700+ that attend this show. Most of the companies that we interacted with were in the medical device space. There were over 13,500 attendees. Some of the people that stopped by the Smith Metal Products booth were not familiar with metal injection molding, so we had the opportunity to educate some people as well. Hopefully, they will take what they learned and incorporate it into designs they are working on.

At both shows, it was fun to talk to companies about their designs and how we can help them. We were thankful to receive a lot of interest and explain why Smith Metal Products is a vendor that can help make a design a reality. Until next year!

Tradeshows!

Thu, 26 Dec 2024 16:08:22 GMT

Tradeshows coming up

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Merry Christmas

Mon, 23 Dec 2024 19:52:14 GMT

This is a subtitle for your new post

Merry Christmas to those that celebrate. Smith Metal Products is closed tomorrow, December 24, and Wednesday, December 25 in observance of the Christmas holiday.

We will return to the office on Thursday, December 26, ready to collaborate with you.

Hopefully, you get some time to relax and spend time with friends and family.

Happy Holidays!

Can Metal Be Used for Injection Molding?

Mon, 16 Dec 2024 21:17:16 GMT

I know plastic is used in injection molding, but is it possible to use metal?

The answer is yes and no. Yes, metal can be used in injection molding, but not by itself. In order to get the powdered metal to take the shape of the mold and hold the shape, about 20% of plastic is added to approximately 80% powdered metal. These pellets are called feedstock and they are melted and pushed into the mold.

After this point, the part is not complete like it may be with plastic injection molding. The metal part needs to go through the debinding process in order to remove all of the plastic. You cannot leave the part alone after debinding, because it is very fragile and you can think of it like a sandcastle like structure. Then the metal parts go through the sintering process to strengthen the part and remove the holes that were left behind by the plastic.

We most commonly use stainless steel powder. Titanium is another metal that we commonly work with. There are some metals that are not compatible with our process. We do not use aluminum, zinc, brass, magnesium or copper in the metal injection molding process.

If you want to learn more about the whole process, see the "What is MIM?" section of our website.

Plastic Products Company

Mon, 04 Nov 2024 16:11:40 GMT

Smith Metal Products is a part of Plastic Products Company

Did you know that Smith Metal Products is a division of Plastic Products Company? Plastic Products Company has ten locations, with Smith Metal Products being the only location that manufactures using metal injection molding.

Their locations are located in:

Lindstrom, MN

Princeton, MN

Center City, MN (Smith Metal Products)

Lebanon, KY

Greenville, KY

Greenfield, TN

West Branch, IA

Moline, IL

Seneca, SC

Phoenix, AZ

Each Plastic Products Company location was carefully selected to support our customers. With plants in several states, multiple process choices, a wide range of presses, and an a la carte menu of services ranging from design through order fulfillment, you can tell us what you need and we’ll make it happen. Our vision is clear… to provide our customers with the best possible Plastic Products by constantly improving our processes and techniques.

If you would like a quote on a plastic project, we would be happy to get you in touch with the right people. See the Contact Us page to send us a message. You can also request a quote from Plastic Products Company here: https://www.plasticproductsco.com/contact-us/request-for-quote/

What size?

Fri, 01 Nov 2024 15:48:02 GMT

What size parts can you make using metal injection molding (MIM)?

Not all parts are good candidates for metal injection molding (MIM).

One factor is the size of the part being produced.

If a part is too big, it is not a good candidate for MIM. At Smith, we typically work with parts that measure less than three inches long. Compatible parts usually way under 100 grams. Most of the parts we currently make are under 50 grams.

If you want an easy way to think about it, parts that are smaller than a fist are usually a good size for metal injection molding.

Have questions? Let's collaborate!

Feel free to send over questions or files to dfm@smithmetals.com

Thu, 31 Oct 2024 20:40:36 GMT

What is an esop?

We are still celebrating ESOP Month! ��

What is an ESOP?

An Employee Stock Ownership Plan (ESOP) is a unique and empowering business model where the employees themselves become the proud owners of the company. At Smith Metal Products, we believe in sharing our success and wealth directly with the incredible individuals who make our business thrive. Through our ESOP, our employees are not just workers; they're stakeholders in our collective success.

Why Choose an ESOP Company Like Smith Metal Products?

�� Ownership & Control: When you join an ESOP company like ours, you become more than an employee; you become a co-owner. Your hard work translates into a stake in the business.

�� Financial Security: At Smith Metal Products, we're committed to not just providing you with a job but also with a path to long-term financial security. As an ESOP participant, you're building your retirement nest egg and financial future with every project which you contribute.

�� Culture of Collaboration: ESOP companies foster a culture of collaboration and teamwork. When everyone is invested in the company's success, you'll find colleagues who are genuinely committed to helping you grow and succeed.

�� Transparency: In an ESOP, financial information is shared openly, giving you a clear understanding of the company's performance. You'll be well-informed about the health of the business and your own investment.

�� Motivated Workforce: Employee ownership encourages a motivated and engaged workforce. When you have a stake in the game, you're driven to perform at your best, leading to both personal and company success.

�� Long-Term Benefits: Working for an ESOP company is an investment in your future. As the company grows, so does the value of your ownership stake.

At Smith Metal Products, we believe in the power of collective ownership and the immense potential it offers to every member of our team. Join us, and you'll not only be building a career but also a brighter and more prosperous future for yourself and your family.

If you're looking for a company that champions its employees and wants you to share in its success, Smith Metal Products is the place to be. Take the next step in your career journey and explore the incredible opportunities that our ESOP-powered company has to offer.

If you are interested in exploring career opportunities at Smith Metal Products, please fill out the contact form here: sales@smithmetals.com

Continuing to serve

Wed, 30 Oct 2024 19:23:36 GMT

Helping at Feed my starving children

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Serving the community

Mon, 07 Oct 2024 16:54:45 GMT

Serving the community to celebrate esop month!

Last week Smith Metal Products got together with our parent company, Plastic Products Company, to serve the community. We had a great time interacting with our coworkers and those within the community. The community meal takes place each Monday at Zion Lutheran Church in Chisago City, MN from four to six pm.

In 2011 the program was started by Zion Lutheran Church, Chisago Lake Lutheran Church, Trinity Lutheran Church and First United Methodist Church in the Chisago Lakes area. Everyone is welcome (income bracket or age do not matter). Volunteers make these meals possible and a variety of groups help serving. We are grateful to have the opportunity to participate each year.

Fresh landscaping

Fri, 04 Oct 2024 20:38:16 GMT

October is ESOP Month!

Wed, 02 Oct 2024 15:05:46 GMT

Celebrating Employee ownership month at smith metal products!

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Celebrating National Tradesperson Day

Fri, 20 Sep 2024 15:00:38 GMT

Honoring the Hardworking Craftsmen and Women at Smith Metal Products

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Why Smith Metal Products?

Mon, 19 Aug 2024 20:16:14 GMT

Why Use Smith Metal Products for your metal injection molding needs?

Why Choose Smith Metal Products for Your Metal Injection Molding (MIM) Needs?

When you need precision, quality, and reliability in Metal Injection Molding (MIM), Smith Metal Products is the clear choice. Here’s why:

1. The Employee-Owned Difference

Since Smith Metal Products is employee-owned, everyone that works here cares about the quality of the parts shipping to our customers. Employee-owners are focused on creating the best products possible for our customers while keeping their costs down.

2. Expertise and Experience

With decades in the MIM industry, Smith Metal Products offers deep expertise and a proven track record, ensuring high-quality outcomes for your projects.

3. Advanced Technology

They utilize state-of-the-art equipment and cutting-edge MIM technology to deliver precision and efficiency that meet the highest standards.

4. Quality Materials

Only the best raw materials are used, backed by rigorous quality control to ensure durability and performance.

5. Custom Solutions

Smith Metal Products provides tailored MIM solutions to meet your specific needs, whether for complex designs or large volumes.

6. Exceptional Service

From consultation to delivery, their customer service is top-notch, ensuring a smooth process and exceeding expectations.

7. Competitive Pricing

They offer high-quality MIM at competitive prices, balancing cost efficiency with exceptional results.

Choose Smith Metal Products for superior MIM solutions that blend expertise, technology, and customer care.

Why work for an employee-owned company?

Fri, 16 Aug 2024 20:00:44 GMT

Smith Metal Products - 100% employee-owned

Smith Metal Products is 100% Employee Owned!

Not everyone is familiar with employee-owned companies. So, you may wonder, why work for an employee-owned company?

1. Greater sense of ownership: As an employee owner, you have a stake in the success of the company. This can give you a greater sense of pride and motivation in your work.

2. Financial benefits: You can share in the company's financial success through the stock ownership program.

3. Long-term stability: Employee-owned companies tend to have lower turnover rates, as employees are more invested in the company's success and are less likely to leave for other opportunities.

4. Greater stability: In an employee-owned company, decisions are often made with the long-term success of the company in mind. This can lead to a more stable and secure work environment.

5. Culture of transparency: Employee-owned companies tend to have a culture of transparency, where employees are kept informed about the company's performance, goals, and strategies. Our CEO regularly communicates with employee-owners.

6. Strong company values: Employee-owned companies often have strong values and a strong sense of community, which can contribute to a positive work culture and employee satisfaction.

If you would like to discuss becoming a part of our employee-owned company, contact us through the employment tab at the top of the website under "about us."

Eric, Smith Metal Products' intern

Wed, 24 Jul 2024 19:46:37 GMT

Eric

Meet our intern, Eric!

"I am majoring in Materials Science & Engineering at the University of Wisconsin-Madison. I always clicked with math and science in high school which translated to an engineering degree, but I had no idea which one particularly interested me. I first looked towards other engineering programs without even knowing of Materials Science. I ended up discovering it after looking into majors related to chemical engineering, my first choice of a major, but switched after finding out that chemical wasn't exactly my cup of tea. Materials Science still has a good background in chemistry but with a broader scope on the world in how makeup and properties affect how materials act. I haven't turned back since declaring.

In my first summer as an intern at Smith Metal Products, I am getting my lay of the land first by learning all the steps of the metal injection molding process. This includes participating in the work involved at each step for various parts we produce to help me get a feel for the true work that goes into the production of just a singular part. I provide assistance to the engineering team in their various projects whether that is working with a customer or doing some testing. I also conduct data collection and analysis of parts and materials to help diagnose problems and create a record to note changes and trends.

This has been a new experience for me living out here near Center City so I have been trying to enjoy some of the nice scenery and outside activities around here. Otherwise, I have recently been getting into cooking, exploring with different cuisines and recipes. I love to listen to music at any free moment I have as I love to listen to all different genres of music so it never gets old for me. I love to play games, especially card games which I can get addicted to very quickly and this happens a lot when I discover/rediscover games. I also love to travel with several countries under my belt already, but I plan to visit many different countries on all the continents throughout my lifetime.

I have loved every second of my experience here at Smith Metal Products as the entire team is so welcoming and friendly. I have felt right at home here and it's been great to learn from all the experience that walks into the building each morning. I am very excited to see what the rest of the summer holds."

Welcome, Eric!

Meet One of Our Interns, Carl!

Thu, 11 Jul 2024 21:37:03 GMT

Carl was kind enough to agree to an interview. You can learn more about him by reading his answers below.

1. What are you studying and how did you decide to study that subject?

I am studying Manufacturing Engineering at North Dakota State University (NDSU) and have begun pursuing an MBA which I will finish a year after I complete my undergraduate degree. I first considered engineering after a mentor recommended that I look into it. While I was earning my Associate of Science, with an emphasis in Engineering, a recruiter from NDSU came and advocated their Industrial & Manufacturing program at which point I experienced the proverbial “Click.” Further inquiry into the specific field confirmed my inclination as I grew more excited about becoming a part of creating goods and products locally.

2. What are you working on as an intern at Smith Metal Products?

This is my second summer as an intern, I now have enough experience and a thorough enough understanding of operations to provide support to the engineering team. Much of my time is split between assisting an engineer in one of their projects or implementing Engineering Change Orders (ECOs) for production use. One project I have enjoyed is creating work instructions for a 3D scanner and using said scanner to analyze tests or samples.

3. What do you like to do in your spare time?

I’m a social butterfly. If there is some activity to do with people, I am on my way if not already present! I am also a motorcycle enthusiast. If the weather is clear, I love taking my sportbike out to some winding back roads or taking a short road trip to any nearby recreational area. A past work experience in the bartending industry sparked a creative outlet in me. I enjoy mixing beverages (both alcoholic and non-alcoholic) to entertain family and friends; some claim that they can’t order certain drinks anymore because they pale to the ones I’ll make them at home. I am a very avid musician, playing both piano and guitar. I absolutely love playing with sounds and melodies making up my own tunes and short scores.

4. Is there anything else you would like to share?

Something that has been a monumental blessing to me at Smith Metals is that the engineering team is both good at what they do and extremely helpful and gracious in answering all my questions. Whether it be where a file is located for the third time, or an Excel shortcut to help save time, I have never felt inferior or incapable while working with anyone.

Thanks for spending your summers with us, Carl!

Using Outsourced MIM Part Production For Firearms, Weaponry And Defense Components Is Less Costly Than Buying And Operating A Machining Center In-House

Thu, 04 Jul 2024 04:53:25 GMT

When does it make more sense to use outsourced MIM part production than to buy and operate a machining center and do the work in-house? MIM is metal injection molding. It is an alternative process instead of machining parts out of raw metal stock. Many original equipment manufacturers of firearms and defense products are mandating that their part suppliers outsource to secure price advantages while maintaining strict quality requirements.

With price pressures and quality requirements getting more stringent by the day, MIM often is the answer. This brief article provides a simple analysis for making the choice to insource or outsource.

A New Or Existing Part Project Requires A Process Evaluation

Starting with the premise that an existing or new part project requires a process evaluation, the following considerations enter the picture. Foremost is an answer to this question – is your part project a viable MIM candidate? Metal injection molding often is a more effective process to achieve precision parts while eliminating machining. That’s because MIM parts are precise, net shaped parts that are produced faster, and usually with no secondary operations. But not all parts qualify for this highly cost-effective alternative solution. Check the following to see if your production application meets these criteria:

Annual volumes of 10,000 pieces or more (the more the better).

Under 100 grams/3.5 ounces finished part weight.

All dimensions of the component 3 inches or less.

Maximum wall thickness of 3mm (0.125 inch) or less (or cored out to this thickness).

Must be ferrous metals (no aluminum, copper, brass, zinc, or magnesium).

Medium to high complexity.

Possibility of merging multiple component assemblies into one part.

Possibility of reducing part weight and/or increasing part strength.

Smith Metal Products Cost Comparison for Machined part versus MIM part:

CNC Part: $8.25 Each

MIM Part: $2.50 Each

$825,000 for machine, labor, etc. $100,000 for 4 molds (average mold cost is $20,000)

100,000 pieces machined (4 parts 25,000 each) $150,000 for 100,000 pieces molded (4 parts 25,000 each)

Year 1 $825,000 or $8.25 per part Year 1 $250,000 or $2.50 each

Not included in the above comparison is what a machining center is costing your company when not making parts. That’s a big cost factor to include in every analysis. By comparison, when outsourcing using MIM production, you pay only for the parts ordered, not for idle machine time or other related downtime experienced with in-house production.

Remember, the above is a generalization and serves as a starting point. Every process application is different. But the numbers above are based on 20 years experience making MIM parts at Smith Metal. So the formula is a valid one.

Also, a MIM supplier has part and mold design experience that can reduce per part cost even more. And by using a USA based MIM supplier like Smith Metal, good jobs are created and kept where they belong – here at home.

Request a quote, Part Evaluation, or call us today at 651-257-3143 .

Smith Metal Products Adds Titanium Metal Injection Molding (TiMIM) To Its MIM Molding Capabilities

Thu, 04 Jul 2024 04:52:03 GMT

Smith Metal Products adds Titanium Metal Injection Molding (TiMIM) capabilities to its MIM Molding portfolio of materials that include stainless steels, alloys and ceramics.

TiMIM involves mixing powdered Titanium metal with a binder material to compose a feedstock capable of being handled by injection molding equipment. Metal injection molding allows complex Titanium parts to be shaped with precision in a single operation and in high volume as compared to traditional Titanium machined metal components.

Adding TiMIM Molding capabilities opens a new, wider range of component applications for Smith Metal Products, where strength-to-weight ratio parts are desired. It is often accomplished with superior features using Titanium compared to other strong but much heavier metals like steels.

TiMIM part features can include undercuts, varying wall thickness up to 0.125″ or 3mm. TiMIM parts also accept many surface finishes including anodizing and electro polishing and can be finish machined if necessary.

“We are excited to have taken delivery of dedicated Titanium Metal Injection Molding (TiMIM) equipment,” stated general manager, Todd Jensen. “Our Employee Owner-Operators are now trained on the equipment and process. We have received successful TiMIM molding verification”, Mr. Jensen reported.

Titanium metal injection molding often is a more effective process to achieve precision parts while eliminating machining. That’s because TiMIM parts are precise, net shaped parts that are produced faster and usually require no secondary operations. But not all parts qualify for this highly cost-effective, alternative solution.

About Smith Metal Products: Smith Metal Products 100% Employee owned (ESOP) and operates a state-of-the-art 65,000 square foot facility, that is ISO 9001:2008 Certified and ISO 13485:2016 Certified. The company’s controlled documentation system assures customers of consistent set-up and repeatability on every production run.

The company operates the latest electric molding machines, continuous and batch debind and sintering furnaces, solvent debinding systems, 5-axis CNC machining and grinding centers, ceramic kilns, coining, laser etching/engraving and inspection lab. Smith also provides rapid prototyping and a complete array of value-added services including plating, laser welding, heat treatment, surface finishing and polishing, assembly, final pack out and more. Design for Manufacturability assistance is a core belief and is a free service at Smith. The company manages single and multi-cavity, hot runner and unscrewing mold design and builds at local domestic tool shops near the facility.

Request a quote, Part Evaluation, or call us today at 651-257-3143 .

Critical Components In Grasping Forceps Precisely Manufactured Using Smith Metals MIM Process — Eliminates Need For Costly Machining

Thu, 04 Jul 2024 04:50:54 GMT

Pivot point components used in a wide range of medical grasping instruments are precisely manufactured using the metal injection molding process (MIM) from Smith Metal Products.

Pivot point components provide natural dexterity in grasping forceps, retractors, needle drivers and similar advanced medical instruments. These critical pivot point components are precisely manufactured using the metal injection molding process (MIM) provided by Smith Metal Products.

The pivot points pictured measure 0.50″ x 0.1875″ x 0.25″ and have tolerances of ±0.0015″. Part features included undercuts, parallel holes and perpendicular shafts – all produced accurately with Smith MIM process. These net shaped MIM produced components required no machining saving both material and machine time.

The pivot point design makes possible unique two-bladed instruments with a specific medical function. For example, grasping fine tissues, suturing with tiny needles, dexterity to perform surgical, obstetric and dental procedures. These two-bladed instruments are designed in many configurations with a handle for manipulating, compressing and grasping motions — all made possible because of the pivot point components robust design versatility.

Smith Metal Products MIM process manufactures these pivot point components to close tolerances with extra durability so the instrument functions reliably with repeatable accuracy. Smith Metals provides a better solution over similarly configured components that require complex precision machining. By metal injection molding 7-4 or 316 stainless steel, the pivot point components pictured meet the quality and durability requirements for these grasping instruments.

MIM is often a preferred process to achieve small precision medical device components. That’s because MIM parts are pre¬cise, net-shaped and can be produced faster than machining and usually with no secondary operations. If a high tolerance needs to be held and cannot be entirely MIM molded, Smith uses CNC machining equipment to achieve tighter specifications while still being more competitive than complete machining of parts.

Parts that are suitable for MIM processing include those that have complicated geometries in annual volumes of 10,000 pieces or more and a finished part weight of less than 100g (3.5 oz). All dimensions of the component should be 3 in. or less, and the maximum wall thickness should be 3 mm (0.125 in.) or less.

Request a quote, Part Evaluation, or call us today at 651-257-3143 .

Small Electronic Components Are Precisely Manufactured Using Smith Metals MIM Processes – Net Shaped Completed Parts Need Little Or No Secondary Operation

Thu, 04 Jul 2024 04:47:52 GMT

Smith Metal Products specializes in metal injection molding (MIM) of soft metal alloys and an array of other metals for small electronic and electrical components.

Ideal for the fast-changing needs of the telecom and electronic markets, Smith Metal Products MIM processes utilize the latest technology that are built around an automated production process. Parts begin when metal powder is suspended in a binder or feed stock which is then injection molded into a tool. The part then goes through a debinding and sintering process to form a full dense metal part. The result are parts that are very precise, net-shaped and can be produced faster than machining and usually with no secondary operations.

Smith Metals specializes in manufacture of many electrical/electronic components including: high voltage power connectors, PCB terminal blocks, smart phone components, solenoids, micro switches, heat sinks, microwave, filter and switching components as well as components for NEMA rated enclosures plus many more.

Costs for Smith Metal components are often up to 50 percent less than other part making processes, highly important in today’s competitive electrical/electronic markets. Faster too. With fewer setups coupled with the speed of metal injection molding, turnaround time from concept to component completion can save weeks of waiting time.

What are the ideal part parameters for the MIM process? Parts most suitable include those made from a full range of alloy materials, including soft metal, stainless steels and Titanium. Ideal parts have simple to complicated geometries and a finished part weight of less than 100g (3.5 oz). All dimensions of the component should be 3 inches or less with a maximum wall thickness of 3 mm (0.125 in.) or less. Annual volume requirement for efficiently produced and priced electrical and electronic components is 10,000 parts or more.

Part designers note: Program Management is an important element in Smith Metal’s MIM processes. This includes complete process engineering, designing and implementing automation, quality assurance, assembly, packaging, product fulfillment and distribution.

Request a quote, Part Evaluation, or call us today at 651-257-3143 .

Smith Metal Products Announces 3D Binder-jet Metal Printing For Quick-turn Prototype MIM-Like Parts

Thu, 04 Jul 2024 04:46:42 GMT

Smith Metal Products adds quick-turn 3D Binder-Jet Metal Printing parts for customers to evaluate and verify their product run utilizing a MIM-like process without the cost of building a test mold. Now manufacturers can easily see, touch and evaluate comparable prototype MIM-like parts produced on Smith Metals advanced 3D Binder-Jet Metal Printing additive production system.

Smith Metal’s 3D Binder Jetting is the only form of metal powder 3D printing where a part is fully formed before thermal energy is used to sinter or fuse the metal particles. This ensures that the final part’s micro-structure is correct to obtain high quality functional and performing parts. Binder Jetting uses a liquid binding agent and is sprayed onto a thin layer of powdered metal particles. Repeating this one layer at a time, the resulting prototype parts are then cured and sintered at high temperatures, creating the final part. Just like Smith Metals MIM parts, 100 percent of the binder is removed during the sintering process.

Smith Metal reports that printing prototype parts is faster and more versatile versus producing expensive test molds for metal injection molding or CNC machining costly prototype parts. Lead time for these prototypes is reduced substantially and allows customers to make adjustments quickly before the final MIM mold is established. 3D printed prototype parts give customers added confidence for their designs with successfully manufactured parts.

Smith Metal’s new 3D Binder Jet Metal Printing capability is designed to support a customer’s research and development efforts with a bridge to MIM molded parts. This new capability is especially desirable for reducing time-to-market developmental programs. In addition to not requiring time-consuming and expensive mold building to evaluate MIM parts, the new process can eliminate and/or significantly shorten lead time from R&D into full volume production.

Available part materials for this new prototype capability include all those available in Smith Metals standard MIM offering. These include low-alloyed steels, stainless steel, most ferrous metals and titanium.

Available part sizes range up to 3 inches long by 0.25 inches thick and weigh up to 100 grams. A Smith Metals Expert will be happy to provide free basic Design for Manufacturability (DFM) recommendations to help you optimize your part designs for MIM production. MIM achieves medium to complex metal parts quickly while eliminating extensive machining. Parts suitable for MIM processing include those that have annual volumes of 10,000 pieces up to several million. Finished parts are net shape accurate with in-house finish machining available for closer tolerance features. Ideal MIM part candidates include firearms, defense, medical, dental, orthodontics, computer, aerospace automotive, appliance and recreation applications.

Request a quote, Part Evaluation, or call us today at 651-257-3143 .

Smith Metal Products Announces Expanded Machining Capabilities For Extending MIM Net Shape Parts To Include Fine Tolerances, A “MIM Hybrid Solution”.

Thu, 04 Jul 2024 04:42:57 GMT

Smith Metal Products adds CNC lathe to in-house machining capabilities making Smith one of the largest MIM molders with significantly more CNC machines and advanced secondary processing capabilities in the USA. Smith Metal’s machining capabilities include CNC 5 axis machining, CNC turning, coining, laser etching/engraving now with 12 in-house machine tools, CNC machinists and CNC programmers. Smith also has established external sources for polishing, lapping, grinding, and EDM wire cutting.

Smith Metal Products calls it their MIM Hybrid Solution for taking MIM net shaped parts beyond the common achievable MIM molding tolerances, stated Jim Beyer Account Manager. “We’ve seen a big increase in interest for MIM parts requiring fine tolerances which are beyond MIM molding capabilities. Secondary, post-process machining is often needed to produce these very precise round holes, threaded holes and smooth, flat surfaces for interfacing with other parts.”

MIM is often a more effec¬tive process to achieve precision parts while eliminating machin¬ing because MIM parts are pre¬cise, net-shaped parts that are produced faster and usually with no secondary operations. If higher tolerances need to be held and cannot be MIM molded, Smith’s MIM Hybrid Solution to achieve tighter specifications is utilized while still being more competitive than complete CNC machining of parts.

Smith Metal Products produces MIM parts for a variety of industries including: automotive, aerospace, firearms, medical, dental, recreation and appliance. Materials available for MIM molding range from stainless steel, steel, titanium, and include most all ferrous materials. Parts that are suitable for MIM processing include those that have annual volumes of 25,000 pieces or more for a single component, or 3 or more parts that have annual usage of 10,000 or more and a finished part weight of less than 100g (3.5 oz). All dimensions of the component should be 3 in. or less, and the maximum wall thickness should be 3 mm (0.125 in.) or less or can be cored out to have thinner wall sections. Smith will help you fine tune your designs to improve manufacturability and reduce costs. MIM parts must be ferrous metals.

Smith Metal Products operates a state-of-the-art 65,000 square foot facility that is ISO 9001:2008 Certified and ISO 13485 compliant. The company’s controlled documentation system assures customers of consistent set-up and repeatability on every production run. A quick-turn 3D Binder-Jet Metal Printing process is also available for customers to evaluate and verify their product run utilizing a MIM-like process without the cost of building a test mold.

Request a quote, Part Evaluation, or call us today at 651-257-3143 .

The MIM Advantage Versus Titanium or Inconel Parts Requiring 50% Or More Of the Material To Be Removed

Thu, 04 Jul 2024 04:41:44 GMT

Smith Metal Products has announced its Metal Injection Molding cost advantage over costly high-performance metals requiring significant machining to achieve the final part geometry. “When Titanium, Inconel or other expensive metals in bar, rod or blocks require substantial hog-outs or hollow-outs, a sintered MIM part may cost less than the raw material alone prior to machining”, stated Todd Jensen, General Manager at Smith Metal Products.

With MIM feedstock only costing approximately 20 – 25% more than raw Titanium or Inconel, the final NET shape for a MIM part uses approximately 50% or less material volume than the raw unmachined materials. Additionally, machining time costs money, and in some cases excessive material is left on the parts just to save money, even though that added weight is not desired. Therefore, a significant cost advantage comes into play for Smiths MIM capabilities and presents cost advantages and great opportunities for product manufacturers.

In recent months, Smith Metal Products has landed new projects for aeronautics, firearms and medical components due to the high cost of many high-performance materials. These projects were previously machined parts and fit the MIM criteria being typically less than 100 grams and lengths up to 4″ by 0.25″ inches thick or can be “cored out” to have thinner walls sections. Smith will even help you trim down your part designs with free basic Design for Manufacturability assistance. Annual volumes for MIM components start at roughly 15,000 and range into millions per year.

Smith Metal Products 3D Binder Jet Metal Printing capability is designed to support a customer’s research and development efforts with a bridge to MIM molded parts. This capability is especially desirable for reducing time-to-market developmental programs. In addition to not requiring time-consuming and expensive mold building to evaluate MIM parts, the new process can eliminate and/or significantly shorten lead time from R&D into full volume production.

Request a quote, Part Evaluation, or call us today at 651-257-3143 .

Smith Metal Products Receives Federal Firearms License (FFL) For Performing Sub-Contracting Services Using MIM Molding Capabilities In Production Of Military, Defense And Firearm Components.

Thu, 04 Jul 2024 04:40:44 GMT

Smith Metal Products has announced it has received the Federal Firearms License (FFL) and adds to its other accreditations that include ISO 13485, ITAR and ISO 9001:2015. This reinforces our quality commitment to producing components with unbeatable levels of precision, strength, and durability, at competitive prices” stated Jim Beyer, Sales Manager at Smith Metal Products.

Smith Metal Products advanced “bridge to MIM” molded parts capability is supported by 3D Binder Jet Metal Printing capability and is designed to help with customer’s research and development efforts. This capability is especially desirable for reducing time-to-market developmental programs. It provides form, fit, function and feasibility testing before mass production. In addition to not requiring time-consuming and expensive mold building to evaluate MIM parts, this capability can eliminate and/or significantly shorten lead time from R&D into full volume production. Quick-turn short runs are also available.

Often-times components that require an FFL by the manufacturer also need to be made from High Performance and expensive materials like Titanium and Inconel. Smith already has experience processing some of these materials and is also willing to develop processes for other high-performance materials as needed. Sometimes MIM parts out of these expensive materials for extensively hollowed out parts can be provided at “near-net shape” for less than the raw bar stock needed for machining parts prior to performing any machining.

The company operates the latest 3D Binder Jet Metal printing, electric molding machines, continuous and batch debind and sintering furnaces, catalytic debinding systems, 5-axis CNC machining and lathe centers, ceramic kilns, coining, laser etching/engraving and inspection lab. Smith also provides rapid prototyping and a complete array of value-added services including plating, laser welding, heat treatment, surface finishing and polishing, assembly, final pack out and more. Design for Manufacturability assistance is a core belief and is a free service at Smith. The company manages single and multi-cavity, hot runner and unscrewing mold design and builds at local domestic tool shops near the facility.

Smith Metal Products is 100% Employee owned (ESOP) and operates a state-of-the-art 65,000 square foot facility, that is ITAR, ISO 9001:2015 and ISO 13485 certified and holds FFL license. The company’s-controlled documentation system assures customers of consistent set-up and repeatability on every production run.

Request a quote, Part Evaluation, or call us today at 651-257-3143 .

Medical Biopsy Forceps, Graspers and Instrument Handles Are Ideal Candidates For Bridge To MIM Starting With 3D Binder-Jet Metal Printing Prototypes.

Thu, 04 Jul 2024 04:39:18 GMT

Biopsy Forceps pictured, and similar Medical graspers and components are ideal components for Smith Metal Products Bridge-to-MIM process.

Center City, Minnesota: Medical designers are looking for streamlined processes and to reduce time-to-market and are now able to verify a product before committing to expensive mold design and building. Smith Metal Products advanced 3D Binder-Jet Metal Printing additive production system is cost-effective alternative to building test molds or CNC machining prototype parts.

Smith Metal Products quick-turn 3D Binder-Jet Metal Printing provides customers the ability to evaluate, modify and verify their product/components utilizing a MIM-like process. Designers can see, touch and evaluate prototype MIM-like parts comparable to Metal Injection Molded parts in as little as 1-2 weeks. Available part materials for Smith’s 3-D Binder-Jet Printing include stainless steel and other alloys upon request.

Once a design is finalized and approved for production, Smith Metal Products Metal Injection Molding is often a preferred process to achieve small precision medical device components. That’s because MIM parts are pre¬cise, net-shaped and can be produced faster than machining and usually with no secondary operations. If a high tolerance needs to be held and cannot be entirely MIM molded, Smith uses CNC machining equipment to achieve tighter specifications while still being more competitive than complete machining of parts.

The MIM process is suitable for components with complicated geometries in annual volumes of 10,000 pieces or more and a finished part weight of less than 100g (3.5 oz). All dimensions of the component should be 3 inches or less, and the maximum wall thickness should be 3 mm (0.125 in.) or less.

Smith Metal Products operates a state-of-the art 65,000 square foot facility that is ISO 13485:2016 and ISO 9001:2015 certified. Other accreditations include ITAR and Federal Firearms License (FFL).

The company’s controlled documentation system assures customers of consistent set-up and repeatability on every production run. For information about MIM medical device components, call 651-257-3143 or fill out the form below.

Request a quote, Part Evaluation, or call us today at 651-257-3143 .

MIM Medical – The Future Is Now

Thu, 04 Jul 2024 04:37:00 GMT

A variety of MIM components in complex shapes and forms molded by Smith Metal Products.

Medical device designers continue to hear about the benefits of metal injection molding (MIM) to produce components and assemblies for a wide range of medical devices. This once radical method for making metal parts has medical designers increasingly becoming advocates of the MIM process because of its quality, material savings, lower costs in medium to high volumes and its design flexibility.

Where early MIM criticisms centered on process control and repeatability for medical device applications, technology improvements have changed those attitudes for the better. Now, new MIM avenues for even the most difficult medical part designs are practical. Many are made from medically required materials including Titanium as well as more commonly used various grades of Stainless Steel.

While MIM is not a replacement for every metal part application, it has shown strong growth across many industries including medical. How strong? From just $9 million USD in 1986, to $382 million USD in 2004 to over $1.5 billion USD in 2015. Medical applications within those numbers have grown exponentially, according to industry reports.

What Is Medical MIM?

Medical MIM is metal injection molding, and at times, also called powder injection molding. It is differentiated from other types of MIM processes (automotive or aerospace applications, for example) because of specific medical requirements for minimal porosity and part cleanliness. MIM is a net-shape process for producing solid metal parts that combines the design freedom of plastic injection molding with material properties near that of wrought metals.

Smith Metal Products MIM molding line inside 65,000 square foot facility.

Metal injection molding mixes metal powder with a thermoplastic binder and molded into a cavity. The molded part is thermally process (sintered) removing the binder while producing a net shaped, high density component. Because it is a molding process, it is capable of producing an almost limitless array of highly complex geometries in many different alloys. It is also a very good option for cost-effective medium to high volume part production.

Compared to machined and cast parts, Medical MIM costs far less per unit, offers greater design flexibility, is a much faster process in large quantities and provides highly repeatable quality. Medical MIM provides benefits to a full range of medically related applications including retinal, cochlear and dental implants, minimally invasive surgical devices, orthopedic implants, cardiac instruments, pacemakers and many more.

Medical MIM Overcomes Negative Density And Other False Perceptions

A common misconception of metal injection molding, particularly for medical device applications, is that the process yields 96 percent (or less) dense parts. In other words, subsurface porosity has potential for bacterial infestation particularly if the parts require secondary operations such as finishing.

MIM medical device handle

While not all Medical MIM parts require maximum density for bacteria resistance, hot isostatic pressing (HIP) of these medical parts is an often preferred and very effective post-processing solution. The HIP process is used to consolidate metals, ceramic and composite steel for example, HIP can add durability for longer part working life with increased hardness, temperature resistance and overall strength.

Some part designers hold a misconception that MIM parts have cracks and other flaws in them. In the earliest development of MIM technology, part voids occasionally occurred. As the powders into solid dense parts. The HIP process allows for high purity and fine grain powders to form into finished and semi-finished parts with minimal deterioration due to impurities, oxidation or grain growth.

Utilizing the HIP process for Medical MIM parts has additional benefits as well. It may positively alter metal and alloy microstructure of certain preferred medical materials. This process has been refined and improved and part validation procedures were implemented, these problems were eliminated. And because the process is highly repeatable, quality is maintained at high levels throughout production runs.

Part size and dimensional tolerances are important to note. Sintered powder metallurgy technologies generally have a tolerance range from ±0.5% of the nominal dimension down to ±0.038mm or ±0.0015 on features of 7.5mm or 0.300″ or less. It should be noted that every part project has its unique characteristics. Consulting with an experienced Medical MIM supplier can provide part size parameters, along with tolerances and material recommendations.

Material Choices For Medical MIM Continues To Grow For Wider And More Complex Part Applications

Over the last decade, many new alloy materials and improved formulations of existing alloys have been developed with successful Medical MIM application. In fact, the material options are far broader than can be described in this article other than to say, there is probably a material option for virtually every medical part requirement.

Part designers who are educated in the benefits of most commonly used materials in their design work can start their MIM evaluation process from these material categories:

Most frequently chosen MIM material are ferrous alloys stainless steel, iron-nickel magnetic alloy and special ferrous alloys.

Hard materials including cermets and cobalt chromium.

Heavy alloys and copper.

The widest grouping of special MIM materials include titanium, nickel, and molybdenum.

It should be noted that certain MIM suppliers specialize in particular groupings of these materials and may not have experience or capability in all potential MIM materials. Supplier variations on similar MIM parts due to feedstock, molding, cavity, furnace, part placement and other differences can occur. The part designer should base material selection, as well as other relevant criteria, on the supplier’s successful experience with that material.

MIM molded orthodontic brackets and hooks.

Another consideration for Medical MIM is cost. Everyone is familiar with cost pressures that are effecting the health care industry and medical device manufacturing in particular. Medical MIM brings opportunity for significant cost savings both with materials and in the process itself. With Medical MIM, parts are produced in net shape form where material waste is virtually eliminated. Compared to machining, particularly where alloys and exotic materials are machined with significant scrap produced, Medical MIM’s net shape process produces no expensive scrap or lost material.

Additionally, because the process is fast, accurate and highly repeatable, Medical MIM provides savings in production time versus machining, particularly where larger part quantities of parts are required. Material and production cost savings will vary greatly dependent on the design variables of the part. Nevertheless, Medical MIM’s history for cost efficiencies continues to grow, particularly as more challenging and complex part projects are satisfied using the process. Meeting these challenges is a parade of newly developed feedstock materials, including new and improved alloys.

Role Of Medical MIM For Part Miniaturization

Medical MIM makes possible intricate, small and lightweight components that are a challenge for precision machining processes. Medical MIM parts can be produced with thin walls, tight radii and true position geometries. In fact, micro components that are of such complex shape that are impossible to machine can be produced successfully using Medical MIM. An example are tiny check valves that regulate fluid flow into the body through small diameter tubing.

MIM molded component shows detail of a medical device component.

Medical MIM implant applications not only are increasingly suitable but growing within the medical device industry. Medical MIM’s use of biocompatible material alloys (Titanium and Cobalt) are gaining part designers attention. Much progress is being made in this area and the medical part designer is encouraged to stay abreast of these developments.

The Medical Device Designer Challenge – Medical MIM Awareness

Staying up-to-date with Medical MIM progress is a worthwhile investment for today’s medical device designer. Access to the latest information has never been easier with information available on Medical MIM manufacturers websites, from the North American Metal Injection Association and the Metal Powder Industry Federation as well as other sources through a Google search.

Request a quote, Part Evaluation, or call us today at 651-257-3143 .

Discovering Metal Injection Molding (MIM) For New Appliance Design Applications

Thu, 04 Jul 2024 04:36:59 GMT

Jim Beyer, Account Manager

Smith Metal Products, A Division of Plastic Products Company

Attention appliance designers – a smart material option is creating new possibilities for appliance component manufacturing. It’s a material process often overlooked in the appliance industry but offers many metal options, has intricate and complex design opportunities with many attractive finish choices and repeatable precise quality. It conserves metal material compared to other processes, has turnaround time advantages in medium and large quantities while ensuring significant cost savings. That design option is metal injection molding (MIM).

Smith Metal Products produces MIM parts from ID as small as 0.010″ and OD as small as 0.060″ up to lengths of 3.00″ by 0.25″ thicknesses.

Why MIM And Why Now?

Driven by constantly changing consumer preferences, the appliance industry has never been more demanding of innovation for functionality, appearance, quality and economy. Like automobiles and smart phones, appliances have a “new look” every year and with it, new functions including newly engineered operating features as well as new exterior cosmetics. To stay ahead of this curve, appliance designers should look to MIM as a favorable option for design enhancements. Once thought of as a radical method for making metal parts, MIM is now an accepted and widely used process in demanding industries such as aerospace, automotive and medical. MIM’s time has arrived for the appliance industry.

Where outside component suppliers to the appliance industry over the years consisted mostly of metal fabricators, plastic molders and precision machine shops, alternate metal processors have arrived on the scene. Leading these are MIM specialists with the technology, experience and large scale capabilities positioned to take center stage. Here’s how:

Metal Injection Molding (MIM) Technology Has Come Of Age

Metal injection molding (MIM) is a net-shape molding process for producing solid metal parts that combines the design freedom of plastic injection molding with superior material properties near that of wrought metals.

Dedicated Smith Metal Products MIM facility has newest, high capacity molding machines and continuous debinding and sintering furnaces. All on-site, needed support equipment includes mold-making, laser etching/engraving, inspection lab and more.

Metal injection molding mixes metal powder with a thermoplastic binder and is molded into a cavity. The molded part is thermally processed (sintered) removing the binder while producing a net shaped, high density component. Because it is a molding process, it is capable of producing an almost limitless array of highly complex three dimensional geometries in many different metal alloys. It is a very good option for cost-effective medium to high volume part production.

Compared to machined and cast parts that require finishing operations, MIM customarily costs far less per unit, offers greater design flexibility, is a much faster process in large quantities and provides precise and highly repeatable quality. MIM materials that are ideal for appliance applications include various grades of hardened steel, stainless steel, nickel-based alloys, ceramics and many others.

With these advantages and design freedom, MIM provides benefits for a large range of possible appliance related component applications including valves and valve lifters, connectors, locks, hinges, handles, supports, gears and many other appliance components including multiple parts combined efficiently molded into a single component.

What Are MIM’s Advantages Over Other Processes?

For many years, appliance manufacturers have used powdered metallurgy, plastic molding and precision machining processes in their designs. A comparison reveals several advantages for MIM:

MIM parts provide cosmetic appeal and have the necessary strength required by the application. Shown is a handle made from stainless steel.

MIM is a superior process to powder metallurgy (PM) because MIM parts have greater metal density and three times the fatigue strength. MIM parts tensile strength is consistent with the metal selected for the process. Also, PM is limited to 2D features while MIM allows complex geometry including undercuts, holes perpendicular to the main axis and precision 3D features.

MIM is often a superior process to precision machining. Each machined feature adds time and cost to the part price. When excess material is left in the part to save time and removal cost, excess weight is retained. In contrast, MIM parts can have many features incorporated into the tooling with excess material cored out, saving manufacturing time, material, part weight and money in the final component cost.

MIM is superior to plastic components because MIM parts are conductive, magnetic, strong, stiff, tough, chemically resistant and can operate at temperatures far over the melting range of most polymers.

Recognizing Good Appliance Part Candidates

MIM should be considered when part production quantities are over 10,000 pieces, are an appropriate size range, have complex shape, require material performance and necessitate reduced cost. MIM almost always has a cost advantage where the shape complexity is outside the range of the other manufacturing processes previously described.

Electronic components can be great MIM candidates with excellent mechanical properties such as micro-switches, connectors, solenoids, heat sinks, optic connectors and distribution frames.

Part size is important because MIM is not a large part process. Parts measuring 3 inches in all directions or smaller and weigh 25 grams or less are the best MIM candidates. Combining multiple parts into a single component (assembly) is often possible with MIM to eliminate screws, adhesive bonding, soldering, welding while reducing both weight and the cost of multiple components. Light-weighing is a long-term appliance design goal. Refrigerators, stoves and dishwashers are large, heavy to assemble, ship and install. The MIM process can help lighten that load.

Shape complexity is an area where MIM is strongest. MIM is often specified for components ranging from 20 specifications (dimensions, locations, surface finish, material density, etc.) on the design drawing to over 250 specifications. Surface finish flexibility is one of MIM’s many specification features attractive to appliance designers. From matte, stainless steel and highly polished surface finishes and color shades, there’s everything cosmetically that a designer could envision that’s possible and practical when specifying MIM.

MIM Turnaround Time

Appliance manufacturing cycles are tight with demands for just-in-time delivery required from part suppliers. MIM suppliers are in tune with demanding production and delivery schedules with experience in aerospace, automotive and medical industries. So naturally requirements for appliance manufacturers can be met equally as well.

Every MIM project begins with mold design and build which can take up to 16 weeks. Once the tooling is set, manufacturing time for batch quantities of 2,500 and higher usually can be accomplished in 4 weeks or less for “as sintered” parts.

The appliance designer should think in terms of the initial mold cost and the price of a one year quantity of parts. Then amortize both over the projected design life of that part. With a minimum annual requirement of 10,000 pieces for starters, the appliance manufacturer can easily specify quarterly part quantities and delivery with an anticipated 4-week lead time. Releases should run at no less than 2500 to 3000 parts with three or four releases a year. Compared to both inside or outsourced precision machining for needed parts, this type of MIM relationship is far more consistent and reliable both in terms of quality, price and on-time delivery.

The Appliance Designer Challenge – More MIM Awareness

Staying up-to-date with MIM progress is a worthwhile investment for today’s appliance designer. Access to the latest information has never been easier available on the Smith Metal Products website, from the North American Metal Injection Association and the Metal Powder Industry Federation as well as other sources through a Google search.

Request a quote, Part Evaluation, or call us today at 651-257-3143 .

Metal Injection Molding Of Titanium And Stainless Steel Provides Cost And Quality Advantages For Today’s Aircraft Manufacturers

Thu, 04 Jul 2024 04:36:58 GMT

Jim Beyer, Account Manager

Advanced aerospace materials using the metal injection molding (MIM) method are providing an alternative, and often better processing method than casting and machining. Important, smaller aerospace components that never make headlines in aerospace manufacturing are candidates for cost savings, weight savings, durability improvements and even enhanced cosmetic appearance using the MIM process.

Smith Metal Products 65,000 sg ft facility has capacity to handle high volumes of parts required by the Aerospace industry.

Today’s commercial and military aircraft require huge quantities of fasteners, screws, seatbelt components, wing flap screw seals, bushings and dozens of similar related components. As an example, there are an estimated 700,000 components in a Boeing 737NG with over 7000 of those planes built to date. Traditional manufacturing methods of current aircraft components more often than not require die casting and value added processes such as machining, metal finishing and plating. With today’s MIM technology, these older methods come up short by comparison.

Use Of MIM Is Historically Proven As An Appropriate Aerospace Manufacturing Process And Is Even More Appropriate In The Current High Volume Aircraft Era

In-the-know aerospace designers have specified MIM for key aircraft components since as far back as the 1980’s. These parts range from latches and fittings to seat belt assemblies and a wide range of adjustment levers. Similarly, Smith Metal Products has been producing many aircraft components dating to the company’s MIM startup in the mid-1990’s. From an industry standpoint, MIM hasn’t attracted the number of customers and users of its technology that it rightly deserves. Until now when designers are searching for better ways to ensure quality while saving money with their designs.

The pace of new aircraft designs and sheer volume of new planes manufactured have ramped up considerably compared to the 1980’s. Just in the ten-year period from 2007-2016, over 45,000 commercial and military aircraft were built, according to Aerospace and Defense Manufacturing 2017 Yearbook. And for the future, over 49,000 aircraft are projected to be manufactured between 2017 and 2026. There’s tremendous component volume in these new aircraft quantities and MIM has a preferred role. Here’s why:

Metal Injection Molding (MIM) Technology Meets The Challenges Of The Aerospace Age

Just as composite fiber has replaced aluminum in fuselage and wing structures and ceramics have replaced key engine components, MIM is replacing the smaller, traditional metal components. Here’s why:

Metal injection molding mixes metal powder with a thermoplastic binder and is molded into a cavity. The molded part is thermally processed (sintered) removing the binder while producing a net shaped, high density component. Because it is a molding process, it is capable of producing an almost limitless array of highly complex three dimensional geometries in many different metal alloys. Among these are stainless steel, Titanium and other custom ferrous alloys preferred by the aerospace industry.

What Are MIM’s Advantages Over Other Processes?

For many years, aerospace manufacturers have used powdered metallurgy, plastic molding and precision machining processes in smaller part designs. A comparison reveals several advantages for MIM:

MIM is a superior process to powder metallurgy (PM) because MIM parts have greater metal density and three times the fatigue strength. For safety reasons, aerospace components must provide maximum durability often well past the service life of the aircraft. Also, MIM parts tensile strength is consistent with the metal selected for the process. In other words, a MIM processed part has the tensile strength of the original material. Also, powdered metallurgy parts are limited to 2D features while MIM allows complex aerospace geometry including undercuts, holes perpendicular to the main axis and precision 3D features.

Shown on left is a molded green part prior to sintering. Part on right is a sintered to final size. Part is a tool for fastening specialize airplane screw heads.

MIM is often a superior process to precision machining, a common aerospace component manufacturing method. However, each machined feature adds time and cost to the part price. When excess material is left in the part to save time and removal cost, excess weight is retained. And today’s aircraft designs strive for lighter weight. In contrast, MIM parts can have many features incorporated into the tooling with excess material cored out, saving part weight, manufacturing time, material and money in the final component cost. Smith Metal Products offers free Design for Manufacturability assistance, and will help designers identify areas where component wall thickness are excessive, and then make recommendations for alternate, cost-saving designs and lower tooling costs.

Electronic components can be great MIM candidates with excellent mechanical properties such as micro-switches, connectors, solenoids, heat sinks, optic connectors and distribution frames.

Recognizing Good Aerospace Part Candidates

Part size is important because MIM is not a large part process. Parts measuring 3 inches in all directions or smaller and weigh 25 grams or less are the best MIM candidates. Combining multiple parts into a single component (assembly) is often possible with MIM to eliminate screws, adhesive bonding, soldering, welding while reducing both weight and the cost of multiple components. Light-weighing is a long-term aircraft design goal. The MIM process can help lighten that load.

Cockpit components, seat components and seat belts are just a few examples which can be great MIM candidates. Properties include excellent mechanical, strength, appearance, light weight and much more.

Shape complexity is an area where MIM is strongest. MIM is often specified for components ranging from 20 specifications (dimensions, locations, surface finish, material density, etc.) on the design drawing to over 250 specifications. Surface finish flexibility is one of MIM’s many specification features attractive to aircraft designers. From matte, stainless steel and highly polished surface finishes and color shades, there’s everything cosmetically that a designer could envision that’s possible and practical when specifying MIM.

MIM Turnaround Time

Aircraft manufacturing cycles are tight with demands for just-in-time delivery required from part suppliers. MIM suppliers are in tune with demanding production and delivery schedules with experience not only in aerospace but also automotive and medical industries. So naturally requirements for aerospace manufacturers can be met equally as well.

The aircraft designer should think in terms of the initial mold cost and the price of a one year quantity of parts. Then amortize both over the projected design life of that part. With a minimum annual requirement of 10,000 pieces for starters, the aircraft manufacturer can easily specify quarterly part quantities and delivery with an anticipated 4-week lead time. Releases should run at no less than 2500 to 3000 parts with three or four releases a year. Compared to both inside or outsourced precision machining for needed parts, this type of MIM relationship is far more consistent and reliable both in terms of quality, price and on-time delivery.

The Aircraft Designer Challenge – More MIM Awareness

Staying up-to-date with MIM progress is a worthwhile investment for today’s aerospace designer. Access to the latest information has never been easier available on the Smith Metal Products website.

Request a quote, Part Evaluation, or call us today at 651-257-3143 .

Automotive Metal Injection Molding Explained

websitebuilder@thryv.com — Thu, 04 Jul 2024 03:09:37 GMT

Complex, high-volume parts are ideal for this process.

For high-volume, high-precision needs of many automotive applications, metal injection molding (MIM) is a growing, though largely overlooked, process that could result in significant cost savings.

Industry statistics state the overall process has grown from $9-million in 1986 (the original patents were awarded in 1980) to $382-million in 2004 to more than $1.5-billion in 2015. The sweet spot for metal injection molding covers high-volume, small parts of relative complexity. For automotive, this includes brake components, rocker arms, injector nozzles, and numerous fittings and connectors.

Small, complex, high-volume parts could benefit from significant process savings from metal injection molding.

The concept of using the injection molding process familiar to plastics processors to shape a metal excites many design engineers, especially when they learn the final part properties are the same, if not better, compared with most machining processes. MIM succeeds in part because there is little material loss; typically 98 percent of the purchased raw material ends up in final products.

Most common engineering alloys can be injection molded, but about 30 alloys dominate the applications. The most popular alloys are austenitic stainless steels (AISI 304L and AISI 316L). After injection molding a combination of the metal powder and a polymer binder, the binder is extracted and metal particles are subjected to a high-temperature sintering treatment. Capillary forces between the small particles make the resulting structure very dense and give it a slightly shrunken component that is essentially full density with tensile and hardness properties equivalent to handbook values.

Educational Mission

Jim Beyer, account manager at metal injection molder Smith Metal Products, says educating potential users on MIM process savings is an ongoing mission. One of the keys to economic success is to apply MIM to complicated geometries, those that already require extensive machining. Further gains come by adding cores, holes, or other mass-reduction features, which can advance lightweighting goals. MIM excels when the component complexity is high and performance demands require excellent properties. It wins against casting since it has better dimensional control and a smoother surface finish. MIM is best applied to large production quantities, as it does require mold tooling. Several parts have reached production quantities in excess of 10-million parts per year.

Most of the metal or ceramic powders used in MIM are between 1 and 40 µm. Typical ratios are about 60 percent metal powder and about 40 percent polymeric binders. Depending on the metal powder, a steel or stainless steel mixture constitutes about 94 percent powder by weight. Lower-density powders may range to 86 percent powder and high-density powders like tungsten may require as much as 97 percent powder. Binders melt at relatively low temperatures to allow easy mixing and molding. The combination of powder and binder is termed “feedstock” and is available from a number of suppliers. Many firms mix feedstock to their own specifications.

Not Traditional Powder Metallurgy

Some engineers confuse MIM with traditional press-sinter powder metallurgy (PM). Standard powder metallurgy forming relies on vertical axis compaction to press a coarse powder into a compact shape. Die compaction is best at forming squat shapes that are easily ejected from the tooling. The ejection step requires the sides be parallel, a restriction in geometry not required for MIM. Thus, in MIM undercuts and holes are possible perpendicular to the main axis.

Dimensional control is the critical difference. MIM components are formed with uniform density and the scatter in final component mass and dimensions is small. For PM, the standard protocol is to use larger powders versus MIM and to sinter at lower temperatures for shorter times to avoid distortion during sintering densification, resulting in lower properties. As a result, MIM strengths are about two-fold higher than PM, Smith Metals says. Fatigue strength is more than three-fold that of PM, and impact toughness is eight-fold higher.

Automotive applications for MIM started to escalate with use in turbochargers, fuel injectors, control components (clock mounts, entry locks, knobs and levers), and valve lifters. The process has found global acceptance.

Request a quote, Part Evaluation, or call us today at 651-257-3143 .

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What Is Metal Injection Molding? Why Manufacturers Trust It

Understanding the Basics of Metal Injection Molding

How the Process Works

What Types of Parts Are Produced With Metal Injection Molding?

Common Components Produced Through MIM

Industries in Chicago That Depend on Metal Injection Molding

Medical Device Manufacturing

Automotive Manufacturing

Aerospace and Industrial Applications

Why Manufacturers Choose Metal Injection Molding

Consistency and Precision

Cost Efficiency for Large Production Runs

The Importance of Quality Control in Metal Injection Molding

Key Quality Standards in MIM Manufacturing

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Scalability for Growing Manufacturing Demands

Scalability Benefits

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Why Precision Manufacturing Matters in Today’s Industrial Market

Contact Smith Metal Products for precision manufacturing solutions

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The Importance of Choosing Experts for Metal Fabrication

How Professional Installation Ensures Structural Integrity and Safety Compliance

Long-Term Durability Through Skilled Fabrication and Installation

The Cost Benefits of Professional Metal Fabrication and Installation

Navigating Building Codes, Permits, and DC-Specific Challenges

Smith Metal Products: Experience You Can Rely On

Secure Quality and Precision

Manufacturers & Metal Injection Molding for Precision Parts

The Traditional Precision Parts Manufacturing Challenge

What Is Metal Injection Molding?

Overcoming High-Cost Regional Barriers With MIM

The Benefits of Metal Injection Molding for Manufacturers

Tighter Tolerances

Lower Waste

Excellent Surface Finish

Scalability and Mass Production

Industries Benefiting From Metal Injection Molding in San Francisco, CA

The MIM Process: Full Production

Why MIM Is the Future of Precision Manufacturing in San Francisco, CA

Harness the Power of Metal Injection Molding Today!

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What Is Metal Injection Molding, and Why Is It Ideal for Medical Applications?

Why Boston Is a Growing Hub for the Metal Injection Molding Medical Industry

How Smith Metal Products Is Leading Metal Injection Molding Medical Technology in Boston, MA

The Future of Medical Manufacturing With Metal Injection Molding Medical Techniques

Transform Your Medical Device Manufacturing With Metal Injection Molding Medical Technology

Expert Metal Injection Molding Medical in Boston, MA

Why Boston’s Medical Manufacturers Are Turning to MIM

Why Metal Injection Molding Is the Smart Choice

The Future of Medical Manufacturing Starts in Boston

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