THE INNOVATIVE PROCESS FOR PRECISION COMPONENTS.
In the MIM process are the technique and presses of injection molding of plastic parts used. It describes the production of complex metal parts by means of injection molding of a mixture of metal powder and thermoplastic polymer resin. The resulting, sprayable granules are called feedstock. After casting, the binder is removed, and the part is sintered at high temperatures. Through this process, we have a diverse selection of forming capabilities and materials. It is particularly suitable in the production of metal parts of complex geometry in medium and large series.
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1. Mix
As a first step in feedstock production, the fine metal powder is mixed with an organic binder to form a homogeneous mass.
2. Feedstock
After granulation, the metal mixture – the feedstock – is ready and can now be processed by injection molding.
3. Injection molding
At elevated temperature, the liquefied feedstock is now filled into a closed mold. The mold is first filled completely and then plasticized. The resulting green compact has all the geometric properties of the finished component.
4. Relieve
Now the green compact is taken out of the injection molding machine. In a two-step process, thermal or catalyzed debindering, the binder is removed. This can take up to 24 hours. What remains is a purely metallic component.
5. Sinter
After debinding, a shaped body remains, also known as brown component. To turn the brown component into an element with the desired geometric and mechanical properties, it must be sintered at high temperatures. Thereafter, the component can be further treated if necessary.
6. Final inspection
Without exception, we perform a visual inspection of all our casting products. The entire scope of all quality control related criteria and activities will be adjusted according to the customer’s requirements.
PROCESS OF THE POWDER INJECTION CASTING-METHOD
- Mix
As a first step in feedstock production, the fine metal powder is mixed with an organic binder to form a homogeneous mass.
After granulation, the metal mixture – the feedstock – is ready and can now be processed by injection molding.
- Injection molding
At elevated temperature, the liquefied feedstock is now filled into a closed mold. The mold is first filled completely and then plasticized. The resulting green compact has all the geometric properties of the finished component.
- Relieve
Now the green compact is taken out of the injection molding machine. In a two-step process, thermal or catalyzed debindering, the binder is removed. This can take up to 24 hours. What remains is a purely metallic component.
- Sinter
After debinding, a shaped body remains, also known as brown component. To turn the brown component into an element with the desired geometric and mechanical properties, it must be sintered at high temperatures. Thereafter, the component can be further treated if necessary.
- Final inspection
Without exception, we perform a visual inspection of all investment casting products. The entire scope of all quality control related criteria and activities will be adjusted according to the customer’s requirements.
FURTHER INFORMATION
Case-hardened steel and tempered steel
Stainless steel and tool steel
Further materials
PROCEDURES IN COMPARISON
In comparison to other processes, such as press sintering or investment casting, the MIM process scores particularly through high precision and the ability to implement complex shapes or special material requirements. Metal powder injection molding is used where complex geometries and low error rates are desired. Small, multi-layered precision parts, which can only be manufactured at high cost using other methods, are mass-produced with the MIM process. Particularly difficult-to-process materials, such as titanium or stainless steel, can be used productively, since there is no need for assembly and joining steps. Even threads, holes, logos or other inscriptions can be incorporated exactly into the component. However, since the MIM process is tool-bound, the cost of the tool must be amortized over the quantities.
ORIGIN
The process has been known for almost a century: The first ceramic casings for spark plugs were produced through this method as early as 1920. However, it did not really get into the industry until 1980 – initially with MIM were produced small, high-precision metallic components for industrial goods and handguns. In the meantime, metal powder injection molding has become indispensable for the industry. It has established itself as a highly economical production method for large-series products, which is used particularly with high complexity.
ADVANTAGES
- High dimensional accuracy
- First-class surface quality
- Low production costs
- Unique detail strength
- Economical even with medium quantities
- Production of complex parts
- Great geometric freedom of design
- Less elaborate editing
- Relative density of 95-98%
- Better adhesion of corrosion protection treatments
- Internal & external threads can already be formed during casting
- Good dimensional tolerances of +/- 0.5%
TESTING OPTIONS
- 3D laser or measuring probes
- Notch impact strength
- Yield strengths
- Chemical analysis
- X-ray
- Fluxing
- Ultrasound
- Tensile strengths
- According to customer requirement
SURFACE TREATMENTS
- Blasting
- Electropolishing
- Galvanizing (chromium-6-free)
- Passivation
- Painting
- Powder-coating
- Anodization
- Priming
- Barrel finishing
- Cathodic dip painting
- Sand or glass bead blasting
FACTS
| Standard weight: | 0,001 – 0,150 kg |
| Materials: | Steel, stainless steel, titanium, hard metal and copper |
| Production: | Asia |
| Certified acc. to: | DIN ISO 9001, 14001, TS 16949 |
| Finishing: | Company-owned CNC processing centers Heat treatment in accordance with customer specifications |
| Tolerances: | approx. +/- 0.3% from the nominal dimension |
| Surfaces: | Ra 3,2 |
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ABOUT US
For over 30 years, we have been your contact for the precise, cost-efficient production of cast parts of all kinds. With a wide international network of production sites and suppliers, we will find the ideal solution tailored to your needs. We are happy to consult you individually and extensively about the right procedure.
Richter Formteile – Precision in its most efficient form.
Thanks to our efficient production principle, we are significantly more economical than our European market competitors. This means that, with us, you receive high quality at fair prices.
ECONOMIC EFFICIENCY
We pre-finance the total amount of your order and store your products for you in our warehouse in Leonberg. You only pay once you need the goods.
PRE-FINANCING
A large warehouse, a unique production principle and efficient planning ensure that we can make immediate deliveries smoothly and flexibly.
SUPPLY AVAILABILITY
You profit from our extensive international network – we manage the rest. As your German legal partner, we take care of the complete handling.
LEGITIMACY
With us, you get everything from one source – without dealers, but with transparency. We produce in our own production sites and calculate each order ourselves
TRANSPARENCY
With numerous production sites or a wide variety of manufacturing methods, we can guarantee competitiveness in all geometries, weights and materials.
RESOURCES
Our employees have extensive expertise, allowing them to give you professional advice regarding the development of components to find the most cost-effective, ideal solution.
COMPETENCY
SECTORS
Electrical industry
Medical technology
Automotive industry & vehicle construction
Mechanical engineering
Drive & transmission technology
Farming & forestry
Construction industry
Filter technology
Fitting & pumps
Food industry
SECTORS
Electrical industry
Medical technology
Automotive industry & vehicle construction
Mechanical engineering
Drive & transmission technology
Farming & forestry
Construction industry
Filter technology
Fitting & pumps
Food industry
REFERENCES
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OUR PRODUCTS
INVESTMENT CASTING
The precision casting procedure offers unlimited design freedom and allows
us to realize optimal technical solutions for you in an affordable way. All
materials, including steel, stainless steel alloys and aluminium, can be
processed using this method and treated according to your wishes.
MIM
Metal injection moulding combines diverse forming possibilities with a large
selection of materials. This procedure can be used to manufacture very small
parts with great accuracy and optimum surface quality. The method allows us
to produce components with high geometrical complexity in an economically
efficient way, even in large quantities.
SINTERING
Sintered parts impress with their wide freedom of design and high precision.
Production runs with no great loss of material and in only a few efficient
steps. With a large selection of material alloys, the procedure gives you
numerous options: Feel free to talk with us about the material properties you want.
DROP FORGING
Drop forging creates an optimal grain direction, thereby assuring top
component strength. We employ this procedure for the highly cost-effective
production of even large quantities. With over 30 years of experience with
forged parts, we boast outstanding expertise in this field. In a thorough
consultation on procedures and materials, we will discuss your ideas
and goals in order to find the best procedure for you.
PROCESSING / COMPONENTS
We are also happy to take charge of the assembly of your components. In a
personal meeting, we discuss your requirements, objectives and the
necessary investment to realize the most economically advantageous
solution. Our competent employees are also happy to support you in the
selection of materials and in creating an efficient design. You decide what the
scope of our work will be: We are happy to explain your various options.
We never fail to provide you with high-quality products that are manufactured and refined in accordance with the most demanding quality standards. Our certifications attest to this fact. Sustainability, comprehensive quality management, and consistent monitoring and optimisation of production processes are just as much part of our work as is identifying efficient manufacturing solutions.
