We are ENGINEERS and METAL INJECTION MOLDING EXPERTS
HOW DO WE METAL INJECTION MOLD?
MIM offers HIGH VOLUME, INTRICATE METAL PARTS with REPEATABILITY...
We are ENGINEERS and METAL INJECTION MOLDING EXPERTS
OVERMOLDING
Push the boundaries of plastic parts with our innovative overmolding process.
This advanced technique takes your injection molded base and seamlessly combines it with a second material, often a soft, rubber-like TPE. This creates a single part with a unique blend of properties. Imagine ergonomic grips for enhanced user comfort, decorative finishes for a touch of style, or even improved functionality like water resistance.
Overmolding opens a world of possibilities, allowing you to tailor your parts for superior performance, ergonomics and aesthetics.
FIREARMS
We understand the demands of firearm components. At ASH INDUSTRIES, we utilize high-precision injection molding to deliver parts known for their strength, reliability, and dimensional accuracy. Our commitment to quality ensures each component performs flawlessly, meeting the expectations of both manufacturers and firearm enthusiasts.
MEDICAL DEVICES
Overmolding Improves grip and control for surgical instruments like scalpels, forceps, and other instruments. Overmolding also works on hand held devices like nebulizers or blood pressure monitors. If you need enhanced durability and protection for delicate internal components of medical devices like defibrillators or anesthesia machines from impact and external factors. Luer fittings and other connectors benefit from overmolds that create secure seals to prevent leaks of fluids or gases.
Biocompatibility is improved with overmolding for implants that integrate with the body.
watch these videos
The biggest benefit of metal injection molding (MIM) at ASH INDUSTRIES is arguably its ability to achieve complex geometries and intricate details at high volumes, offering several advantages over traditional metalworking methods:
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Cost-effective for intricate parts: MIM excels at producing complex shapes that would be expensive or even impossible to create through machining or other traditional methods.
-
High-precision and tight tolerances: MIM delivers exceptional detail and dimensional accuracy, rivaling traditionally machined components.
-
Mass production capabilities: Unlike some metalworking techniques limited to small batches, MIM allows for high-volume production of identical metal parts.
Exceptional MIM parts come from smarter thinking.
Metal Injection Molding (MIM) is a manufacturing process where metal powder is mixed with a binder to create a moldable material. This material is then injected into a mold under high pressure to form the desired shape. Once formed, the binder is removed through a debinding process, and the metal particles are sintered together to create a strong, near-net-shape metal part. MIM is a cost-effective way to produce complex metal parts in high volume.
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STARTING RIGHT!
DESIGN for MANUFACTURING
Optimizing Your Metal Parts Digitally
Design for Manufacturability (DFM) is your secret weapon for transforming innovative concepts into production-ready injection molded parts. By collaborating with our DFM experts early on, you can identify potential roadblocks like complex geometries or uneven wall thickness. We'll suggest adjustments that optimize your design for efficient molding, minimizing waste and production costs. This ensures your parts are not only functional but also manufacturable, saving you time and money while bringing your vision to life.
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Reduced Production Costs: Streamlined designs minimize material waste, optimize cycle times, and simplify the molding process, leading to lower production costs.
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Enhanced Quality: DFM helps avoid common molding defects like sink marks, warping, or short shots, ensuring your parts meet the highest quality standards.
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Faster Time to Market: By identifying potential issues upfront, DFM allows for a smoother transition from design to production, accelerating your time to market.
WHERE TO BUILD THE MOLD?
YOUR MOLD & IN-HOUSE TOOLROOM
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THE MOST IMPORTANT PART OF THE PROCESS
In-house mold building is a game-changer for injection molding. Imagine seamless communication between design and toolmakers, speeding up development and getting your product to market faster. Direct control over quality ensures molds meet your exact specs, reducing defects. In-house tooling keeps everything streamlined, potentially saving costs. It's a strategic advantage for any serious molding company.
Choosing the right injection molding company for your custom MIM parts is crucial for success.
Here are some key factors in choosing a metal injection molding supplier:
Expertise:
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Experience: Look for a supplier with a proven track record in MIM, particularly for parts similar to yours in complexity and material.
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Design for Manufacturability (DFM): Choose a supplier with DFM expertise who can analyze your design and suggest improvements for optimal MIM production.
Capabilities:
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Material options: Ensure the supplier works with the specific metal material you require for your part.
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Part complexity: Match your part's intricate details with the supplier's capabilities. Some specialize in highly complex shapes.
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Production volume: Select a supplier with the capacity to handle your desired production volume efficiently.
Quality and Cost:
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Quality control: Inquire about their quality control procedures to ensure they meet your standards for dimensional accuracy and surface finish.
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Cost transparency: Get clear quotes that detail upfront costs like tooling and per-unit part costs. Consider hidden fees or potential cost variations.
Additional Factors:
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Communication and customer service: Choose a supplier with good communication practices and a willingness to collaborate throughout the process.
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Lead times: Understand the supplier's lead times for mold creation and production runs to meet your project timeline.
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Certifications: Consider any relevant industry certifications they hold.
By carefully evaluating these factors, you can find a MIM supplier who aligns with your project requirements and delivers high-quality metal parts efficiently.
2
WHERE TO BUILD THE MOLD?
YOUR MOLD & IN-HOUSE TOOLROOM
THE MOST IMPORTANT PART OF THE PROCESS
In-house mold building is a game-changer for injection molding. Imagine seamless communication between design and toolmakers, speeding up development and getting your product to market faster. Direct control over quality ensures molds meet your exact specs, reducing defects. In-house tooling keeps everything streamlined, potentially saving costs. It's a strategic advantage for any serious molding company.
HOW DO WE METAL INJECTION MOLD?
MIM offers HIGH VOLUME, INTRICATE METAL PARTS with REPEATABILITY...
1
IT STARTS WITH DESIGN
DESIGN for MANUFACTURING
ASH FACTS:
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Thermoplastic Injection Molding
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Rotomolding
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Tool & Die manufacturing
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Silicone Molding
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3D Printing Production
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Design for Manufacturing (DFM)
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Low volume 3D production
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3D Plastic Printing
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Metal Injection Molding
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Yes, ASH can help you manufacture your parts in low volume. We can even 3D print your first prototypes. When you want to have less than 1000 but don't want to pay for full production runs we have a flat rate low volume program called SUPERMOLD. This can have many benefits, including a faster time to market and a low initial investment but still allow you to produce high-quality parts.
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Of course NDA's are necessary to protect your IP. We value privacy and confidentiality and that is one of your main reasons for making parts in the USA. NDA's are enforceable here unlike sourcing overseas. Confidentiality is one of the most important factors in choosing a new molding supplier.
We are ISO 9001 compliant and ISO 13485 with a ISO Class 7 medical cleanroom.
Yes we do, besides our founder graduating from Massachusetts Institute of Technology with a degree in 6-1, Electrical Engineering-Hardware, we also have a biomedical engineer, mechanical engineers and other manufacturing engineers on staff to help you think smarter to save money.
GET THE BALL ROLLING
Maybe you don't know which process to use, so let us help with a free engineering consult.
This is where you get great ideas
The earlier you get your supplier involved, the better chance that you will save something big. It could be time, money, functionality or even a new idea.
We specialize in the "tough challenges", the projects that need extra attention, experimentation or a new material. There's no better molding company than ASH to do this.
OVERMOLDING
Push the boundaries of metal parts with our innovative overmolding process.
This advanced technique takes your injection molded base and seamlessly combines it with a second material, often a soft, rubber-like TPE. This creates a single part with a unique blend of properties. Imagine ergonomic grips for enhanced user comfort, decorative finishes for a touch of style, or even improved functionality like water resistance.
Overmolding opens a world of possibilities, allowing you to tailor your parts for superior performance, ergonomics and aesthetics.
FIREARMS
We understand the demands of firearms components. At ASH INDUSTRIES, we utilize high-precision metal injection molding to deliver parts known for their strength, reliability, and dimensional accuracy. Our commitment to quality ensures each component performs flawlessly, meeting the expectations of both manufacturers and firearms enthusiasts.
NET SHAPE?
MIM (Metal Injection Molding) is a process specifically designed to achieve net shape for metal parts as opposed to casting a metal part and then achieving ideal shapes by secondary operations. This means the parts produced through MIM require minimal to no post-processing for their final form.
Here's a breakdown:
Net Shape vs. Near-Net Shape: Net shape refers to a perfect final form achieved directly from the manufacturing process, while near-net shape allows for minimal additional work.
MIM's Advantage: MIM offers a significant advantage over traditional metalworking methods like machining. Machining involves carving away excess material from a solid block, leading to significant waste and requiring precise calculations to achieve the desired shape. MIM, on the other hand, builds the part layer-by-layer using a mold, minimizing material waste and achieving intricate details close to the final form.
Slight Shrinkage: It's important to note that MIM parts do experience between 15% and 30% shrinkage during the sintering process, when the binding material is removed and the metal powder particles are fused together in a 98% dense, no porosity, homogenous component. The shrinkage in a MIM part is predictable according to the content of the original material and accounted for during the mold design stage to ensure the final parts meet the desired dimensions.
The biggest benefit of metal injection molding (MIM) at ASH INDUSTRIES is arguably its ability to achieve complex geometries and intricate details at high volumes, offering several advantages over traditional metalworking methods:
-
Cost-effective for intricate parts: MIM excels at producing complex shapes that would be expensive or even impossible to create through machining or other traditional methods.
-
High-precision and tight tolerances: MIM delivers exceptional detail and dimensional accuracy, rivaling traditionally machined components.
-
Mass production capabilities: Unlike some metalworking techniques limited to small batches, MIM allows for high-volume production of identical metal parts.
Exceptional MIM parts come from smarter thinking.
Metal Injection Molding (MIM) is a manufacturing process where metal powder is mixed with a binder to create a moldable material. This material is then injected into a mold under high pressure to form the desired shape. Once formed, the binder is removed through a debinding process, and the metal particles are sintered together to create a strong, near-net-shape metal part. MIM is a cost-effective way to produce complex metal parts in high volume.
MEDICAL MOLDING
When it comes to medical-grade metal parts, cleanliness is paramount.
ASH offers unparalleled medical molding capabilities with our state-of-the-art, ISO Class 7 clean room facility. This controlled environment minimizes airborne particles and contaminants, ensuring your medical components are manufactured to the strictest standards. This meticulous approach safeguards the integrity of your parts, fostering patient safety and regulatory compliance.
Trust us to deliver medical-grade MIM parts with unmatched quality and precision.
ASH offers unparalleled medical molding capabilities with our state-of-the-art, ISO Class 8 clean room facility. This controlled environment minimizes airborne particles and contaminants, ensuring your medical components are manufactured to the strictest standards.
Trust us to deliver medical-grade MIM parts with unmatched quality and precision.
NET SHAPE?
MIM (Metal Injection Molding) is a process specifically designed to achieve net shape for metal parts as opposed to casting a metal part and then achieving ideal shapes by secondary operations. This means the parts produced through MIM require minimal to no post-processing for their final form.
Here's a breakdown:
Net Shape vs. Near-Net Shape: Net shape refers to a perfect final form achieved directly from the manufacturing process, while near-net shape allows for minimal additional work.
MIM's Advantage: MIM offers a significant advantage over traditional metalworking methods like machining. Machining involves carving away excess material from a solid block, leading to significant waste and requiring precise calculations to achieve the desired shape. MIM, on the other hand, builds the part layer-by-layer using a mold, minimizing material waste and achieving intricate details close to the final form.
Slight Shrinkage: It's important to note that MIM parts do experience between 15% and 30% shrinkage during the sintering process, when the binding material is removed and the metal powder particles are fused together in a 98% dense, no porosity, homogenous component. The shrinkage in a MIM part is predictable according to the content of the original material and accounted for during the mold design stage to ensure the final parts meet the desired dimensions.
GET THE BALL ROLLING
Maybe you don't know which process to use, so let us help with a free engineering consult.
This is where you get great ideas
The earlier you get your supplier involved, the better chance that you will save something big. It could be time, money, functionality or even a new idea.
We specialize in the "tough challenges", the projects that need extra attention, experimentation or a new material. There's no better molding company than ASH to do this.
People also ask:
Metal injection molding (MIM) is a metalworking process in which finely-powdered metal is mixed with binder material to create a moldable "feedstock." This feedstock resembles plastic used in injection molding. The metal-infused feedstock is then injected under high pressure into a precisely designed mold cavity, similar to how plastic is shaped in injection molding. Once formed, the binder is removed through a debinding process, leaving behind a near-net-shape metal part. Finally, the part undergoes a high-temperature sintering process, transforming the metal powder into a solid and robust metal component.
The SUPERMOLD program utilizes specialized inserts to existing molds so we simply machine a small area to make your sample parts in that time frame. The lifetime tooling is then ready for full production runs very quickly.
MIM can produce small parts with complex features, whereas die casting is better suited to larger parts. MIM excels at intricate shapes due to its injection molding nature, while casting is better for simpler, larger parts. Additionally, MIM allows for wider material options, including ferrous metals, compared to casting's usual focus on non-ferrous metals.
CNC machining and injection molding metal (MIM) take opposite approaches. CNC carves away metal for precise, one-off parts, while MIM builds intricate shapes in high volumes using metal powder and a mold. Though both handle various metals, MIM often favors steel due to the sintering process
SUPERMOLDS have a lifetime warranty, but even normal injection molds are carefully maintained by ASH's in-house tool-making facility. Typical lastic injection molds last from hundreds of thousands to over a million cycles but here, a plastic injection mold lifespan is extended to the extreme thanks to our maintenance, structure, SPI classification and materials.
Generally, MIM tends to be more cost-effective than CNC Machining for large production volumes due to economies of scale and faster production rates. The initial high cost of mold creation in Metal Injection Molding is offset by the lower per-unit cost in high-volume production.
Piece-part price for injection molding is going to be significantly lower compared to 3D printing once you reach a high volume of parts. ASH actually brings that minimum down thanks to the SUPERMOLD PROGRAM where you can get less than 1000 parts for less than the cost of 3D printing.
The biggest differences are porosity, strength, cost and energy expenditure. The additional polymers and steps in the MIM process add to the expense of production, and it takes more energy to produce the pieces. Powder metallurgy is less expensive generally and takes less energy, but also produces parts that are not as strong.
watch these videos
OVERMOLDING
Push the boundaries of plastic parts with our innovative overmolding process.
This advanced technique takes your injection molded base and seamlessly combines it with a second material, often a soft, rubber-like TPE. This creates a single part with a unique blend of properties. Imagine ergonomic grips for enhanced user comfort, decorative finishes for a touch of style, or even improved functionality like water resistance.
Overmolding opens a world of possibilities, allowing you to tailor your parts for superior performance, ergonomics and aesthetics.
FIREARMS
We understand the demands of firearm components. At ASH INDUSTRIES, we utilize high-precision injection molding to deliver parts known for their strength, reliability, and dimensional accuracy. Our commitment to quality ensures each component performs flawlessly, meeting the expectations of both manufacturers and firearms enthusiasts.
MEDICAL DEVICES
Overmolding Improves grip and control for surgical instruments like scalpels, forceps, and other instruments. Overmolding also works on hand held devices like nebulizers or blood pressure monitors. If you need enhanced durability and protection for delicate internal components of medical devices like defibrillators or anesthesia machines from impact and external factors. Luer fittings and other connectors benefit from overmolds that create secure seals to prevent leaks of fluids or gases.
Biocompatibility is improved with overmolding for implants that integrate with the body.