Market Prospectus of Powder Injection Molding (PIM)
Powder Injection Molding (PIM) has drastically changed. It has moved from the research and development stages into the production sectors in the electronics, computing, medical devices, and chemicals industries. It is expected injection molding companies will expand at a massive growth rate of between 20-40% in the years to come. With current global sales standing at $200 million. Market shares are led by the US which produces about 40% of total PIM parts while Japan comes second with 30%. Europe, which was more reluctant to take to the product initially, now accounts for about 15% of the market. The current statistics show that the U.S. has twice as many PIM companies as Europe, depicting great growth potential.
Applicability of the Powder Injection Molding Process
PIM products
Briefly, PIM has strength in small, intricate parts with detailed features and tight tolerances. The method has demonstrated its flexibility across diverse applications, including:
- Turbochargers and radial rotors silicon carbide for heat engines.
- Thread guides in alumina for application in textile equipment.
- Hard disc drives magnetic pole pieces of rare earth magnets.
- Electric toothbrush gears are made of stainless steel.
The examples mentioned above prove the potential of PIM to work with any type of material and industry, proving its ability to manufacture high-precision parts economically.
Influence of Raw Materials on the PIM Process
The current developments in PIM technology show the maturity of the technology, especially in controlling the nature of metal and ceramic powders to fit certain uses. Also, current binder systems have been enhanced to lower the defect level and shorten debinding time, which is a crucial aspect of part fabrication.
One possible factor that may enhance the use of PIM is the capacity to enhance component characteristics throughout production as opposed to after. This would provide improvement to surface characteristics: wear and corrosion resistance; as well as the volumetric characteristics: toughness. Some of the universities like Cranfield are already involved in researching means of enhancing the general performance of components right within the PIM process.
Powder Co-Injection Molding (PCM)
One innovation that may be noted here is Powder Co-Injection Molding (PCM) which provides the option to surface treat parts in situ. An example of the process is the use of two barrels, each feeding the same nozzle but injecting different materials into the mold in turns. This is done using a pneumatic valve system which enables control over the skin and core materials.
The process follows these steps:
- Placing the skin material into the mold, and then blowing it up.
- The outer layer is formed by skinning while injection of the core material is done after skinning is complete.
- The final shot of skin material completely covers the core of the sculpture.
During the process, the materials in each barrel may be different from one another. For example, the skin of 316L stainless steel can be combined with a carbonyl iron core. The cost variation between these materials is significant, thereby cutting production costs threefold. Manufacturers can also control the surface thickness layer by varying the ratio of the material injected from each barrel making the process cost-efficient. While at the same time achieving the required material property on the surface.
Furthermore, the secondary phases can be incorporated into the surface material to enhance its performance characteristics. For instance, adding alumina particles to the binder/powder combination for the skin increases its wear capability and makes it appropriate for high-stress applications. (Get more insights about Injection Molding Types)
Applications of Powder Injection Molding
Technological advancement in the powder injection molding industry is a breakthrough in contemporary manufacturing techniques. This innovative technique results in lightweight, highly durable, and at the same time versatile end-use products. Today this method is used in every industry to offer custom solutions to manufacturing needs.
Medical Instruments
Orthodontic brackets are core products of powder injection molding. PIM technology also makes it possible to fashion different types of medical instruments in detail. This way helps create intricate shapes of surgical instruments. Sustaining these applications’ durability and efficiency remains a primary focus in these applications.
Automotive Sector
Automotive components need special strength to perform in highly challenging conditions. PIM technology enables the creation of intricate parts for which durability is critical. It is used in automotive products such as engines and transmissions to guarantee the vehicle’s efficiency.
Electronics Industry
The Electronics sector requires precise and miniaturized components. Due to the high rate of technological development, PIM is highly competitive in producing such parts. This capability is illustrated by connectors and mobile device components. The method also improves the conduction features of electronic applications.
Aerospace
Components for aerospace applications must not be less dense but also have to be mechanically strong. PIM can satisfy these strict requirements using high-performance metals and ceramics. This method provides parts with high quality that meet the stringently required standards in aerospace engineering. Aircraft internal parts are usually made through powder injection molding.