Quality Assurance for Metal Powder Injection Molding

With Quality Assurance to Zero-defect Productions

Metal powder injection molding has in the meantime developed into a mature technology for the large-scale injection-molding production of metal parts. It is therefore of the greatest importance for the industry to minimize scrap at all stages of the process: from feedstock production through the injection molding up to sintering.

The dimensional stability and quality of sintered parts depend greatly on the choice of process parameters at each step of the process. Deviations in the injection molding parameters may, for example, result in dimensional deviations or defects such as cracks, warpage or voids that in the worst case are only discernable after sintering. Therefore the aim must be to obtain information on the anticipated quality of the parts during the respective process step, and to be able to evaluate the influence of deviating process parameters.

Looking at the whole process, zero-defect production requires:

  • Recording and assessment of the quality of both the powder and binder components, and of the feedstock preparation
  • Assurance of the best possible injection molding process by simulating the mold filling process and constant process data recording and evaluation
  • Analysis of the interactions of atmosphere, binder constituents and the metallic powders directly in the debindering and sintering process for reproducible setting of material and part properties