MDM Metal MIM Metal extrusion molding process

Metal Injection Molding (MIM) is a manufacturing process that uses metal powder as raw material to mass produce parts with complex shapes, high precision, and strength. It has become a rapidly developing and most promising new near net forming technology in the field of powder metallurgy, and is known as one of the most popular metal part forming technologies in the world. Due to its relatively new manufacturing process, the accumulation of manufacturing methods and proprietary technology is still insufficient.

Metal extrusion molding process

Metal extrusion molding is a common metal parts processing technology with multiple meanings. Besides the traditional process used for tubes and bars, there is also a newer extrusion molding process – metal injection molding MIM. MIM is a new near-net-shape forming technology for metal parts that introduces plastic injection molding technology into the powder metallurgy field. It combines the design flexibility of plastic injection molding with the strength and integrity of forged metal, providing a cost-effective solution for complex part geometries. MIM processing is one of the fastest-growing high-tech fields in powder metallurgy and industry. Its process typically includes four unique processing steps: raw material preparation, injection molding, debinding, and sintering, used to produce the final part.

1. Raw material preparation

Metal injection molding (MIM) uses a special mixture of metal powder and binder to form a uniform feedstock. Just as metal extrusion requires the preparation of suitable materials, we carefully select high-quality metal powders in MIM to ensure the performance of the final product.

Injection Molding:

The mixed feedstock is injected into a mold to form the desired shape. This step is similar to the extrusion process in metal extrusion molding, but MIM is capable of manufacturing more complex and precise parts.

Degreasing:

Remove the binder, leaving the basic shape of the metal part. Although different from the metal extrusion molding process, this is a unique process step in MIM to ensure product precision and quality.

Sintering:

The degreased parts are sintered at high temperature to tightly bond the metal particles, achieving the required strength and performance. This process is similar to the heat treatment after metal extrusion molding, giving the product excellent physical properties.

PROCESSING ADVANTAGES OF METAL EXTRUSION MOLDING

HIGH-PRECISION MANUFACTURING

METAL INJECTION MOLDING (MIM) CAN PRODUCE PARTS WITH HIGH PRECISION AND COMPLEX SHAPES, FAR EXCEEDING TRADITIONAL MOLDING PROCESSES.

MATERIAL FLEXIBILITY

MIM CAN USE A VARIETY OF METAL MATERIALS, INCLUDING STAINLESS STEEL, TITANIUM, AND COBALT-CHROMIUM ALLOYS, TO MEET THE NEEDS OF DIFFERENT CUSTOMERS. IN CONTRAST, TRADITIONAL MOLDING PROCESSES HAVE RELATIVELY LIMITED MATERIAL CHOICES.

MASS PRODUCTION CAPACITY

COST-EFFECTIVENESS

ALTHOUGH THE INITIAL INVESTMENT IN MIM MAY BE HIGH, ITS COST-EFFECTIVENESS ADVANTAGE IS SIGNIFICANT IN MASS PRODUCTION, SAVING COSTS FOR CUSTOMERS.

APPLICATION AREAS OF EXTRUSION MOLDING

Medical accessories

Hardware components

Automotive parts

3C consumer product accessories

Communication equipment

Metal Injection Molding (MIM) for Building & Construction: Materials, Applications & Advantages

Metal Injection Molding (MIM) is a precision manufacturing process that blends metal powder with a polymer binder to form a feedstock, which is injection-molded, debound (binder removal), and sintered into dense, complex metal components. While not for large structural concrete/steel beams, MIM excels at high-volume, intricate building hardware, smart building sensors, and facade/MEP (mechanical, electrical, plumbing) components—with specific material systems optimized for construction’s harsh environments (moisture, UV, corrosion).

MIM Components for Building & Construction

Facade & Envelope Hardware: Curtain wall brackets, glass panel clips, stone fixing pins, adjustable facade connectors (MIM enables micro-features like threaded holes, undercuts that casting cannot match)

MEP & Plumbing: Miniature valves, pipe fittings, HVAC sensor housings, electrical terminal blocks

Smart Building Infrastructure: Building and Decorative Materials Sensor casings for humidity/temperature/CO2, actuator components for automated windows, security lock mechanisms

Door & Window Hardware: Precision hinges, multi-point lock parts, handle inserts

PROCESS COMPARISON

Comparison items	Metal Injection Molding (MIM)	Precision casting	Machining	Sheet metal stamping
density	98%	98%	100%	100%
Tensile strength	high	high	high	high
Surface smoothness	high	middle	high	high
Miniaturization capability	high	Low	middle	high
Thin-wall capability	high	middle	Low	high
Complexity	high	middle	high	Low
Design tolerance	high	middle	middle	Low
Production capacity	high	middle	Medium-high	middle
Material range	high	Medium-high	high	middle
Supply capacity	high	middle	Low	high

Compared to other metal forming methods, the advantages of MIM extrusion molding are specifically reflected as follows:

Advantages	Specific manifestations
Extremely high degree of design freedom	MIM technology can directly form complex metal parts, just like plastic injection molding, allowing for free design of three-dimensional shapes. In theory, any structure that can be achieved with plastic can be achieved through MIM technology.
Excellent physical and chemical properties	MIM products have a uniform structure and good density. The sintering density can reach more than 98% of the theoretical density, or even approach the theoretical density. Its physical and chemical properties are excellent, and the mechanical properties such as product strength, hardness, and elongation exceed those of traditional processes.
Higher dimensional accuracy	MIM products can achieve a dimensional accuracy of +/- 0.3% in a single molding process. Products with general accuracy requirements do not require post-processing. If combined with other processing methods, even higher dimensional accuracy can be obtained.
More material options	MIM technology can be used with almost any metal material, making it particularly suitable for applications requiring high material properties. For economic reasons, the main materials used include iron-based, nickel-based, copper-based, and titanium-based metals or alloys.
Exquisite appearance	The surface roughness (Ra) of the sintered blank produced by the MIM process can reach 1μm, and dazzling appearance effects can be obtained through various surface treatment methods.
Flexible mass production capabilities	MIM technology allows for flexible adjustments and rapid increases in production capacity, enabling quick responses from a few hundred pieces per day to hundreds of thousands of pieces per day.
Extremely high raw material utilization rate	MIM (Metal Injection Molding) technology has a near-net-shape forming technology with a material utilization rate of nearly 100%, which can effectively avoid material waste.
Significant bulk cost advantages	MIM (Metal Injection Molding) technology offers near-net-shape forming capabilities, providing a significant cost advantage over other processes, especially for products with complex structures, in mass production.

Advantages of MDM Metal MIM

MIM combines the advantages of powder metallurgy and plastic injection molding, breaking through the limitations of traditional metal powder molding processes in product shape. At the same time, it utilizes the characteristics of plastic injection molding technology that can efficiently form complex shaped parts in large quantities, becoming a near net forming technology for modern manufacturing of high-quality precision parts. It has unparalleled advantages over conventional powder metallurgy, machining, and precision casting processing methods.

About MDM Metal Company

MDM Metal mainly provides large quantities, high-quality, and reasonably priced MIM products for customers in various industries worldwide, including metal powder injection molding, metal powder injection molding, powder injection molding, metal 3D printing wires, metal powder injection molding factories, metal powder injection molding factories, powder injection molding factories, MIM processes, MIM processing, and MIM factories. The company has gathered a team of experts in technology, management, and market development from the industry. With years of experience in MIM technology and industrial production operations, the company provides customers with a one-stop solution for MIM product pre design, sample development, and mass production through mdmmetal's mature MIM technology, efficient supply chain management, and fast and effective large-scale manufacturing capabilities.

MDM Metal has gathered a team of experienced experts in technology, management, and market development in the industry. With years of MIM technology experience and industrial production operation experience, MDM Metal provides customers with a one-stop solution for MIM product pre design, sample development, and mass production through internationally mature MIM technology, efficient supply chain management, and fast and effective large-scale molding capabilities. Our business covers over 60 countries and regions worldwide.

Metal Injection Molding Department: We have been focusing on the research and production of MIM products for a long time. The company has advanced production and testing equipment and can produce various complex shaped, high-precision, and high-performance components. With strong capabilities, the company has gradually developed into one of the companies with a well-developed MIM industry chain in the Pearl River Delta. Learn more mdmmetal.com

author

Chris Bates

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