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Engineering
- Flow analysis simulations completed prior to production to understand flow, cycle times, tooling requirements, and materials.
- In-house engineering team with experience, knowledge, creativity, and customer-focused.
- Can produce small, complex parts, or simple shapes & sizes.
- Determination of best materials for specific applications.
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Product Reliability
- Part are very consistent magnetically and dimensionally from lot to lot and part to part.
- Materials used to produce parts are validated prior to production to ensure product specifications are met.
- Able to automate production & quality systems to keep costs down, increase yield, and eliminate waste.
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Material Development
- Greater design freedoms for engineers to use advanced materials and instead of traditional metals.
- Continual research being done on new materials.
- Able to enhance and optimize the magnetics in an assembly when designed correctly.
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Quality Systems & Certifications
- ISO Certifications: ISO9001, IATF16949, ISO14001, OSHA18001, ISO13485.
- Design & Implementation of quality systems per customer requirements.
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Production Process
- Feedstock. Fine powders are mixed with a binder to achieve the maximum density.
- Molding. Similar to plastic injection molding, feedstock is heated, melted and injected into mold cavities at high pressure.
- De-Binding. The process to remove the “green part” within the part, which is mainly the binding agent.
- Sintering. Done to remove pores and give the part its final density and strength.
- Shaping. When needed, shaping tools can bring the parts back into profile under high pressure.
- CNC Machining. If needed due to very tight tolerances, CNC machining after sintering gives the part more accuracy.
- Surface Treatment. This can include sand blasting, polishing, plating, epoxy coatings, etc.
Over molding puts a protective and functional plastic around the entire or partial magnet. Some key points of over molding:
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Select the Proper Plastic
- Will the part be used in an application requiring sterilization of the part?
- Is the thickness of the plastic taken into consideration in the design and magnetic performance?
- Will the part be exposed to water, moisture or fluids?
- Will the part need to withstand drop tests or force?
- What are the temperature requirements during operation?
- Are there any special markings or features that need to be imbedded in the plastic?
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Facts Related to Over Molding
- Over molding is usually considered for high volume applications, or applications that will have a life span of several years.
- Tooling. Over molding requires a tooling charge, mainly for the die required to manufacture the part. Soft tooling can be made, however it is suggested that the final design get locked down and tooling made immediately. For EVT and DVT builds, alternative manufacturing methods may be available.
- Lead Time. Since tooling is required, the lead time is usually longer than other parts.
- Net Shape. In almost all over-molded applications, the parts are produced to final, or near-final size and shape.
Contact Us
To start a conversation about MIM, CIM, or Over Molding requirements, contact one of our technical staff.