This component was redesigned to take advantage of MIM’s processing capabilities. The fabrication process involves a two-plate mold. Due to its geometric complexity, four sides of the part use a design-with-slider interlock system. Both internal channels are formed during the MIM process. Forming the 90-degree internal channels required the use of a hydraulic core-pull slider system. The sensor also comprises several through holes and intricate features which only MIM can produce. Only one flat surface is available for the part to rest on during debinding and sintering. The component is processed close to net shape per print by MIM. The only secondary operation is the tapping of the several MIM pre-formed holes to get threading on them.
A cost savings of approximately 40% was achieved versus the previous casted and machined component.
The entire process generated less than 5% material waste. All material runners from the injection process can be recycled.