MIM
PHILLIPS PLASTICS CORPORATION ™

™
Serving original equipment manufacturers in virtually every market since 1964, Phillips Plastics
Corporation ™ has established itself as one of the premiere sources for the design and manufacture of custom plastic and metal injection molded components. Today, Phillips Plastics employs over 1,600 people in 15 locations throughout the United States. phillipsmetals.com

Metal injection molding (MIM) is an effective way to produce complex and precision-shaped parts from a variety of materials. It is common for this process to produce parts for 50% less than the cost of CNC machining or investment casting. At the same time, the true value of MIM comes from its ability to produce parts with complex shapes, superior strength, and excellent surface finish in combination with high volume manufacturing capability. Total cost savings result from the function of shape complexity, production volumes, size of the part, and material used. Sizes of parts can be up to 150 grams, although most parts produced are less than 30 grams.
Phillips Plastics can meet your smallest requirements, with the capability to mold metal parts in a variety of materials ranging from 0.0001 - 0.003 cubic inches . Tolerances can be held to as little as ±0.0005 inches.

Attention to detail at the mixing step is critical to ensure the homogeneity of the feedstock over the long run. MIM feedstock begins with extensive characterization of very fine (less than 22 micron) metal powders. These powders are carefully hot mixed together with polymeric binders to form a uniform mixture. This mixture is then cooled and granulated to form the feedstock for the injection molding machine.
Phillips’ specially equipped injection molding machines are designed to mold a metal/polymer feedstock. Combining over 42 years of injection molding experience with advanced processing instrumentation and software ensures tight control of this process producing consistent components with unvarying density. If in-cavity pressure transducers indicate the molding cycle is out of predetermined limits, the closed loop feedback system rejects parts automatically.
Most of the advantages of using Phillips’ MIM capabilities are realized in the molding step, where complex contours, holes, small radii, logos, and text can be molded in. The molding process creates virtually no waste since runners can be reground and molded again without compromising the properties of the final part. In the molding area, extensive automation is also employed to palletize parts directly onto ceramic setters.
This automation eliminates the unnecessary handling of parts, providing consistent and cost-effective manufacturing solutions.
The advanced debinding technology used by Phillips is the most efficient form of debinding. Harnessing the power of polymer chemistry, Phillips introduces a catalyst to remove 90% of the binder from the green part. Because catalytic debinding occurs at temperatures below the softening point of the binder, parts are processed with excellent shape and dimensional integrity. After the binder has been removed, the result is termed a “brown” part. The brown part consists of a porous matrix of metal powder and a small amount of binder, sufficient to allow the part to retain its shape.

In the final step, the brown parts are sintered using a temperature and atmosphere profile chosen specifically for the alloy being processed. At the lower temperatures of the sintering cycle, the residual polymer binder is removed. As the temperature increases, sintering begins. Neighboring particles fuse and bond to one another bringing the structure together and reducing porosity. Ultimately, the required physical properties are obtained and densities between 96-99% of theoretical are achieved. During the densification process, depending on the material being processed, liner shrinkage of 14-22% occurs. This shrinkage is predictable and compensated for by over-sizing the mold cavity. Typical as-sintered tolerances are within
± 0.30 to 0.50 (0.003 to 0.005 inches-per-inch).
1
MIM can produce relatively small, highly complex geometries with excellent surface finish, high strength, and superior corrosion resistance. Parts that are well suited for MIM are those that would require extensive machining set-up or assembly operations if made by any other metal forming process.
The major advantage of MIM is its ability to produce complex metal geometries without machining.
If the designer begins work at the concept stage, overall part size and weight can be reduced and multiple components can be consolidated into a single design. By designing components for the MIM process, part count and assembly time are reduced resulting in overall cost savings.
2
1 “Green” or “as molded” parts
2 “Brown” parts. Same size, but
90% of the binder is gone
3 “Sintered” parts. 96+% dense.
Size meets print
3

Metal Powder
(~ 60% volume)
Polymer
(~ 40% volume)
Heater
Bands
Mold
Feedstock
· Powder and polymer binder are hot mixed to produce a homogenous mixture
Feedstock
· Viscosity of feedstock is much higher
· Feedstock density 5-6 g/cm 3
· Advanced instrumentation is required for process monitoring and control
Exhaust Burner
Heater
Coils

ust Burner
Fan
Catalyst
Shrinking Core Mechanism
Process Parameters
· Chemical reaction
· Shrinking core mechanism
· Temperature is below softening point of binder
Process Keys
· Fast (2-4 hours)
· Clean
· No distortion of parts
Secondary
Binder
Brown
Parts
8-10 Preheat and Hot Zones
Continuous Furnace
Sintered
Parts
· Linear shrinkage of 14-22%
· Sintered density of 96-99% of theoretical
· Mechanical and corrosion properties comparable to wrought

The Phillips MIM process ensures customers receive superior quality components in the most compressed time frame possible. Time reductions are achieved by utilizing resins that can undergo debinding five times faster than those used by other metal injection molders.
In addition, part designs are optimized and mechanical properties ensured with Phillips’ product design and development capabilities, which are supported by an expert staff of metallurgists and engineers. Whether prototype quantities or millions of parts are required,
Phillips follows the same quality procedures according to their TS16949: 2002, ISO 14001, and
ISO 9001: 2000 registrations.
MIM molds are similar to those used for plastic injection molding. As in tooling for plastic injection molding, molds are often designed with multiple cavities to reduce processing costs. Phillips’ in-house tooling capabilities can be employed to ensure a seamless line of communication during the tooling phase of the program. Although lead times vary from one program to another, typical MIM tooling lead times are 4-8 weeks. A Phillips representative can assist in determining the cost-effectiveness for individual programs.
For over four decades, Phillips has been providing OEMs with design, manufacturing, and post-molding services. Phillips offers the rare advantage of a true “one-stop shop.” With a full complement of metal, plastic, and magnesium injection molding expertise, the best process is selected for each component.
Phillips’ cross-functional team of manufacturing experts combines forces to promote efficiencies in manufacture and assembly such as insert molding metal components with plastic, designing attachment features for the most effective assembly, and providing comprehensive secondary services – from painting to shielding and assembly.

Phillips’ batch debind ovens and furnaces are equipped to handle a wide variety of MIM materials
Phillips’ metal injection molding facility is equipped with both batch and continuous debinding ovens and sintering furnaces. Continuous debinding and sintering provides the temperature uniformity and consistent processing conditions for a wide range of materials.
The result is excellent dimensional repeatability at the lowest possible cost for programs with extremely high throughput requirements.
Batch sintering compliments Phillips’ continuous furnace capability by providing the flexibility to run smaller batch sizes in product development cycles.
Batch sintering also allows Phillips to run larger parts, in the 120 grams range or higher, that would not be well suited for the continuous furnace process. In addition, with the vacuum capabilities of these furnaces, specialty materials like titanium can be processed.
Extensive automation is employed to maintain constant cycle times and minimize part handling.
Consistency and a lower overall cost to customers are the results.
In A Flash
Phillips’ reputation for producing high quality parts in an accelerated time frame begins at the design phase of a program. At one of two in-house design development centers,
Phillips’ team can create high quality MIM parts in as little as two weeks .

· Superior quality
· Consistent processing
· Shortened lead times
· Optimized part designs
· Superior mechanical properties
· Sampling and prototyping
As a one-stop solution provider, Phillips Plastics offers the following corporate-wide capabilities to supplement all MIM programs:
· Design Development Centers utilize all major CAD platforms
· Industrial design
· Engineering
· Finite element analysis (FEA)
· Moldflow ® analysis
· Rapid prototyping
· Stereolithography
· Insert molding
· Medical molding and assembly
· Multi-shot molding
· Precision decorating
· Low volume molding
· Small parts molding
· Magnesium injection molding
· Micro molding
· Program management
· Supply chain management
· In-house automation
· Three in-house toolrooms
· Clean room molding

Phillips’ continuous debinding and sintering furnace provides quality processing and large volume capacity while maintaining consistent quality
One of the more traditional metalforming processes,
MIM competes on a material and geometry basis directly with investment casting and machining. In other words, similar geometries can be produced in a given material by each of these three processes.
MIM excels when part complexity is high, overall component size is small, and production volumes are 10,000 or more.
MIM competes against die-casting on a geometry-only basis. Here, the same geometries can be produced by both processes, but material choices are different.
Compared with aluminum, zinc, or magnesium die castings, MIM components offer far superior strength, hardness, and corrosion resistance properties. In most cases, the higher properties of MIM come at a slightly higher cost when compared to die-cast components.
MIM may compete economically with stamping or the conventional powder metal process when two or more of these components are combined into a single MIM design. By reducing part-count and eliminating assembly hassles, a lower overall cost can be achieved. The greater design flexibility of MIM allows features like blind holes, threads, and wall thickness changes to be molded-in from the start rather than added later as secondary operations.

The following are guidelines for choosing metal injection molding over an alternative metal forming process:
Machining · MIM designs save material and weight
· Cost savings
· Molding components from a single tool eliminates multiple set-up operations
· Difficult to machine materials can be molded into shape
Investment Casting · MIM can produce thinner wall sections and sharper cutting points
· Better surface finish
· Better for small diameter blind and through holes
· Finish machining required is greatly reduced
· High volumes of small components are produced at lower cost and faster lead times
Die-Casting
Press and Sinter
· MIM alloy selections offer superior corrosion protection
· Superior wear resistance
· Superior strength and hardness
· Larger material selection
· MIM can mold geometries that eliminate secondary operations
· Superior density and corrosion performance
· Superior strength and ductility
· Combining two P/M parts can reduce part count
· Superior magnetic properties

When designing MIM components, the engineer can begin with a clean slate, adding material in uniform wall sections only when needed. This thought process is much different than designing for machining, where reducing the amount of metal removed from a square or round stock can be an important consideration.
Because MIM allows the designer to reduce material content to only what is functionally required, MIM parts are generally smaller and lighter than their machined counterparts.
The MIM designer is also freed from the restrictions imposed by the capability of the machining equipment.
The design freedom with MIM is largely the same as with plastic injection molding. Whether the designer makes improvements by reducing material content, combining multiple components, or by molding in text and logos, the earlier Phillips’ MIM engineers are involved, the greater the chance to experience the full benefits of metal injection molding.
· Complex geometries – parts requiring multiple machining operations are usually good candidates for MIM
· Tolerances ±0.003” to 0.005” per inch
· 150 grams or less in weight, although most
MIM parts are less than 30 grams
· Length of components – less than five inches
· Capability to support various volumes from concept to high volume production

On complex shapes where draft is required, the normal range is 0.25 to 0.50 degrees. In many cases, parts can be produced with no draft.
To avoid internal stresses, voids, and sink marks, walls of uniform thickness are ideal. Thicknesses in the range of 0.050 to 0.250 inches are preferred, but exceptions in both directions are routinely done. Parts have been produced with wall sections as little as 0.005 inch and as large as 0.50 inch. Consult a Phillips’ metal injection molding engineer for details.
Ribs and webs are useful for reinforcing relatively thin walls and avoiding thick sections. They improve material flow and limit distortion, while increasing strength and rigidity of a thin wall. Rib thickness should not exceed that of the adjoining wall.
Fillets and radii eliminate sharp corners, which reduces stress at the intersection of features and facilitates the flow of feedstock into the mold cavity.

External undercuts can be formed anywhere in the part. Internal undercuts can be formed using collapsible cores, but they are generally not considered economically practical. Phillips has the capability to machine internal undercuts as a secondary operation, when required.
External and internal threads can be molded using
MIM technology; however, secondary tapping is usually more precise for internal threads. External threads are normally produced with a small flat area on the parting line of the mold to eliminate potential interference from the parting line.
When designing for the MIM process, engineers should be aware of the following requirements of the molding process:
Parting Line – The parting line is the plane in which the two mold halves meet. To the extent possible, all features should be oriented perpendicular to the plane of the parting line to facilitate removing the part from the mold.
Slides and lifters can be incorporated for components that cannot be perpendicular to the parting line
Gate Location – The optimum location of gates is a balance between product and processing requirements. In general gates should be positioned to direct the flow onto a core pin or cavity wall. Where wall thickness varies, gates should be located so the material flows from the thicker to the thinner sections.
Witnesses – Because a MIM component begins as an injection molded part, witnesses such as parting lines, ejector pins, and gates will be present. When designing critical features into a part, consideration of the location of witnesses should be addressed with
Phillips’ team of experts.
Provisions for Sintering – Metal injection molded parts are typically placed on flat, ceramic fixtures for sintering. Parts with long cantilevers and spans are not self-supporting and generally require ribs, added supports, or custom fixtures for sintering. Whenever possible, the part designs should include a flat surface to eliminate the need for these custom fixtures. For more complex shapes, custom setters can be utilized for highly detailed geometries.

Phillips can provide secondary operations to meet an array of specific requirements. Since typical tolerances for the MIM process are within 0.003 to 0.005 inches per inch, (0.3-0.5%), many parts are sintered to final dimensions. If tighter tolerances are required in certain areas, secondary-machining operations can be applied. Tapping operations can produce internal threads with tolerances tighter than can be achieved via the metal injection molding process. Tumbling and polishing can provide an aesthetic surface. Parts can be heat-treated; black oxide coated, and plated in similar fashion to investment cast or machined parts.
· CNC Machining
- Milling
- Turning
- Grinding
- Tapping
- Lapping
· Surface finishing
- Passivation
- Black oxide
- Nickel
- Gold
- Chrome
- Bead blasting
- Tumbling
- Electro-polishing
- Titanium nitride
· Calibration
- Coining
- Sizing
- Straightening
· Heat Treatment
- Through hardening
- Case hardening
- Annealing
- Ageing
- Tempering

Phillips’ Metal Injection Molding offers several alloys that are used in a wide variety of automotive, electronic, medical, magnetic, and consumer applications.
Injection molded alloys include:
· Stainless steels
· Titanium
· Tool Steels
· Low alloy steels
· Soft-magnetic alloys
· Controlled expansion alloys
· High temperature alloys
Go to phillipsmetals.com for the most up-to-date material selection chart
Phillips’ in-house metallurgy lab provides material characterization and testing services, including tensile testing, fatigue testing, microstructure analysis, hardness, density, corrosion testing, and carbon analysis. Full geometric inspection with Statistical Process
Control (SPC) is available for all components.
These capabilities allow Phillips to maintain tight control of all aspects of the MIM process.
Phillips metallurgist testing the strength of materials and mechanical properties

· Established in 1964, Phillips Plastics is a privately held custom injection molder of plastic and metal
· Phillips Plastics is a technology driven Company, providing contract manufacturing services to original equipment manufacturers in the automotive, appliance, telecommunications, consumer electronics, industrial, medical, defense, and recreational markets
· Fiscal year 2005 sales were approximately $220 million
· Phillips Plastics employs more than 1,600 people; supported by a network of 814 production people, 31 quality assurance people, 20 designers, 166 engineers (includes design, process, and manufacturing), and 115 toolmakers (includes tool managers, coordinators, team leaders, mold makers, mold polishers, machinists, jig and fixture, EDM specialists, and apprentices)
· Total number of presses is 254, ranging in tonnage from 0.44 to 935
· Phillips Plastics consists of 15 locations throughout the United States, occupying over 718, 737 square feet, with total manufacturing square footage equaling
333,658 square feet
· Facilities are certified to ISO 9001, ISO 9002, ISO
9001:2000, ISO 13488, TS-16949, and ISO 14001. Our medical facilities are registered with the FDA for medical device manufacturing. Facility certificates will be supplied upon request
™
Opportunity Development
877.508.0260
info@phillipsplastics.com
phillipsmetals.com

PHILLIPS PLASTICS CORPORATION ™
Material
Low Alloy Steels
42CrMo4(4140) as-sintered
42CrMo4(4140) heat treated
8620
8620 heat treated
4605 as-sintered
4605 heat treated
Fe-2% Ni as-sintered
Fe-2% Ni heat treated†
Fe-8% Ni as-sintered
Fe-8% Ni heat treated†
Stainless Steels
316L
310
N
2 sintered
PANACEA
17-4PH heat treated
420 heat treated
440 B
(sinc and HIP)
440 B heat treated
Yield Strength
(MPa)
≥ 400
≥ 1250
≥ 400
≥ 400
1500
≥ 150
≥ 210
≥ 180
≥ 450
≥ 690
≥ 950
≥ 1300
UTS
(MPa)
≥ 650
≥ 1450
≥ 650
≥ 600
1900
≥ 260
≥ 380
≥ 510
≥ 600
≥ 1090
≥ 1100
≥ 1600
Elongation (%)
≥ 5
≥ 2
≥ 25
≥ 3
≥ 2
≥ 3
≥ 15
≥ 50%
16
≥ 35
≥ 5
≥ 2
Density
(g/cm3)
≥ 7.8
≥ 7.22
≥ 7.50
≥ 7.6
≥ 7.3
≥ 7.65
≥ 7.65
≥ 7.4
≥ 7.4
≥ 7.4
≥ 7.4
≥ 7.55
≥ 7.55
≥ 7.5
≥ 7.5
≥ 7.5
≥ 7.5
Hardness
(HRC)
130-230 HV10
≥ 45 HRC
190-230 HV10
≥ 650 HV1
≥ 150 HV1
≥ 55 HRC
90-110 HV10
≥ 55 HRC
90-140 HV10
≥ 600 HV10
120 HV10
235 HV1
270-300 HV10
38 HRC
≥ 48 HRC
≥ 45 HRC
≥ 55 HRC
† Refers to typical properties for through-hardened Fe-2% Ni and Fe-8% Ni. These alloys can be heat-treated to achieve a range of case or through hardness depending on the application. The corresponding strengths and ductilities vary depending on the heat-treated condition.
1 Mpa = 145 psi
Note:
All properties are typical. Phillips’ Metal Injection Molding does not warranty that these materials are fit for any particular purpose. All materials need to be tested by the customer to assure they meet minimum performance criteria.
©2006 PHILLIPS PLASTICS CORPORATION ™

PHILLIPS PLASTICS CORPORATION ™
Material
Tool Steel
M2 as-sintered
M2 heat-treated
Soft Magnetic Alloys
Fe-50% Ni
F (pure iron)
Fe-3% Si
430
Special Alloys
HX (Hastelloy X) sintered and solution annealed)
Titanium
(CP Grade 4)
Kovar ® (F15)
Tungsten (W) non-magnetic
Yield Strength
(MPa)
≥ 800
≥ 150
≥ 110
≥ 300
≥ 200
≥ 280
≥ 480
≥ 300
UTS
(MPa)
≥ 1200
≥ 400
≥ 230
≥ 500
≥ 350
≥ 610
≥ 550
≥ 450
Elongation (%)
≥ 1.0
≥ 35
≥ 5
≥ 24
≥ 20
≥ 40
≥ 20
≥ 30
Density
(g/cm 3 )
≥ 7.9
≥ 7.9
≥ 7.6
≥ 7.8
≥ 7.5
≥ 7.6
≥ 7.87
≥ 4.2
≥ 7.8
≥1 7.8
Hardness
(HRC)
≥ 50 HRC
≥ 64 HRC
100-140 HV1
50-60 HV10
120-160 HV1
100-150 HV10
140-160 HV10
160-240 HV1
110-140 HV1
320 HV1
1 Mpa = 145 psi
Note:
All properties are typical. Phillips’ Metal Injection Molding does not warranty that these materials are fit for any particular purpose. All materials need to be tested by the customer to assure they meet minimum performance criteria.
Kovar ® is a registered trademark of Carpenter Technology Corporation
©2006 PHILLIPS PLASTICS CORPORATION ™

PHILLIPS PLASTICS CORPORATION ™
C Si Mo Cu Mn Others Material Fe Ni Cr
Low Alloy Steels
42CrMo4(4140)
8620
4605
Fe-2% Ni
Fe-8% Ni
(sintered in H2)
Fe-8% Ni
(sintered in N2)
Stainless Steels
316L
310
PANACEA
17-4PH
420
440 B
Tool Steel
M2
Soft Magnetic Alloys
Fe-50% Ni
F (pure iron)
Fe-3Si
430
Special Alloys
HX (Hastelloy X)
Titanium (CP Grade 4)
Kovar
®
(F15)
Tungsten (W)
Bal.
Bal.
Bal.
Bal.
Bal.
17-20
Bal.
Bal.
Bal.
Bal.
Bal.
Bal.
Bal.
Bal.
Bal.
Bal.
Bal.
Bal.
Bal.
0.4-0.7
1.50-2.50
1.90-2.20
7.50-8.50
7.50-8.50
10-14
19.0-22.0
≤ 0.10
3-5
49.5-50.5
Bal.
28.5-29.5
0.9-1.2
0.4-0.6
16-18
24.0-26.0
16.5-17.5
15-17.5
12-14
16-18
3.80-4.50
49.5-50.5
15.5-17.5
20.5-23.0
0.32-0.42
0.12-0.23
0.40-0.60
≤ 0.10
≤ 0.10
0.4-0.6
0.03 max
0.2-0.5
≤ 0.20
0.07 max
0.18-0.30
0.75-0.95
0.95-1.05
≤ 0.10
≤ 0.10
≤ 0.10
≤ 0.08
0.05-0.15
≤ 0.20
1.0 max
1.0 max
0.75-1.75
≤ 1.0
1.0 max
≤ 1.0
≤ 1.0
2.50-3.00
≤ 1.0
≤ 1.0
0.15-0.30
0.15-0.30
0.20-0.50
2.0-3.0
3.0-3.5
≤ 0.75
4.5-5.5
8-10
3.0-5.0
2.0 max
≤ 1.5
10-12
1.0 max
≤ 1.0
≤ 1.0
1.2-1.5 Nb
0.75-0.90 N
0.15-0.45 (Nb + Ta)
≤ 1.0
≤ 1.0
W 5.50-6.75 V 1.75-2.20
0.5-2.10 Co, 0.20-1.0 W, 0.008 B
Ti Bal. (O ≤ 0.40, N ≤ 0.10)
Co 16.5-17.5
≤ 94% W Bal. (Ni, Cu, Co)
Kovar
® is a registered trademark of Carpenter Technology Corporation
©2006 PHILLIPS PLASTICS CORPORATION ™

PHILLIPS PLASTICS CORPORATION ™
Residual
Induction
Br
(kG)
Coercive
Force
Hc
(Oe)
Maximum
Permeability
µmax
(B/H)
Induced
Magnetic
Field
B25
(kG)
Induced
Magnetic
Field
B50
(kG)
Induced
Magnetic
Field
B500
(kG)
Fe-50% Ni
F (Pure Iron)
Fe-3% Si
430
8
12.4
11.5
6.4
0.125
0.36
0.918
0.92
27,270
14,236
5,215
3,311
14
12.4
11.5
6.4
8
15.7
14.9
12
14.6
NA
NA
--
1 Oerstad (Oe) = 79.55 ampere/meter (A/m)
1 kiloguass (kG) = 0.10 tesla (T)
Note:
All properties are typical. Phillips’ Metal Injection Molding does not warranty that these materials are fit for any particular purpose. All materials need to be tested by the customer to assure they meet minimum performance criteria.
Material
Nimonic 90 after sintering sintered + heat-treated
HIP + heat-treated
Material
CHS-4 after sintering at 20˚C
C Cr Fe Co Al Ti Mn Si Ni
≤ 0.13
18-21
Yield Strength
730 MPA
790
≤ 1.5
UTS
1220 MPA
1270
15-21 1.0-2.0
Elongation
14
33
3.0-4.0
Density
8.0
8.18
≤ 1.0
≤ 1.0
Hardness
350 HV10
385 HV10
Bal.
C Si Mn Cr Ni Mo V W Fe
2.2
1.6
Yield Strength
≤ 600 MPA
1.0
UTS
≤ 800 MPA
12.0
39.0
Elongation
≤ 2.0
6.0
Density
≤ 7.9
0.9
0.5
Hardness
≤ 33-37 HRC
Bal.
©2006 PHILLIPS PLASTICS CORPORATION ™

© 2006 Phillips Plastics Corporation
™