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

Smith Metal Products - 100% employee-owned

Eric

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

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) 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 .

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 .

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 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 .