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Automotive parts undergo the kind of abuse that requires high strength and high performance. At the same time, since they are often manufactured in great volume, cost effectiveness remains a major concern. These are the perfect requirements for using
Metal Injection Molding
(MIM), the process used by
AFT
to produce a rotorkopf for a large automotive parts client.
The rotorkopf is used in a wireless throttle application. The most interesting feature of the part is the fact that the outside diameter of the part is made of magnetic 430 stainless steel while the inner disk is made of 304 non-magnetic stainless steel. The MIM process allowed the two materials to be sinter-bonded together, eliminating the previous welding process — and thus cutting labor costs — while giving the client the magnetic application they desired. Furthermore, while the part meets the form, fit and function the customer expects, it also is reported to exhibit magnetic properties about 10% greater than the conventional method of fabrication. This has provided the client with an added benefit that has remained very popular.
In production since 1997, the rotorkopf is manufactured in quantities in excess of one million per year and weighs an extremely light 12.5 grams.
Metal Injection Molding
is ideal for applications where high volume, complex geometry, high performance and low cost are required. Applications for MIM include automotive parts, power tools, medical instruments, as well as computer and electronics parts.
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