Redesigned from a previously 100%-machined component, this component uses innovative fabrication techniques to achieve its many intricate details. One of the more advanced techniques for this part is the use of a custom-designed tray for staging the parts in sintering. This special design minimized distortion in the parts during the sintering operation and minimized the need for post-secondary operations. Only a cold-work coining step and a single post-machined operation was required for a single dimension in order to bring the part to within specification.
The redesign from a machined component to a MIM component reduced the per part cost by 60%. The redesign reduced the need for machining down to a single feature post-sinter. Functional and industry-standard testing was performed by the customer in conjunction with the mating assemblies. The parts manufacturer used in-process CMM verification during the final machining operation.