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Maximizing Housing Performance Through MIM: A Case Study

Explore how Metal Injection Molding (MIM) enhanced housing application in telecommunications electronics. Discover the functional requirements met, competing technologies, and the economic advantages of MIM.

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Maximizing Housing Performance Through MIM: A Case Study

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  1. MIM Case Study - Housing Application: Telecommunications Electronics Housing Functional Requirements: Magnetic isolation, heat dissipation, easy assembly Competing Technologies: Machining Overall Size: LxWxH = 32 mm x 24 mm x10 mm Part Weight: 15 grams Material: MIM-2200

  2. Key Characteristics- Housing Threads added as a secondary operation to accommodate protective lid Side holes for assembly and logo created through slides Thin sections < 1 mm Flatness for heat dissipation, proper assembly - < 0.1 mm

  3. MIM Case Study - Housing • Why MIM? • Production rates > 50,000 per month at peak easily handled by a 4-cavity tool • Replication of details (radii, logo, hole locations, etc.) in MIM was excellent with little variation • Good magnetic properties for shielding • No problem with plating (Ag over Ni) • Little material waste • Fewer burr removal problems • Side slots for assembly handled in tooling

  4. MIM Case Study - Housing • MIM Issues • Flatness < 0.1 mm required for heat dissipation and assembly of fragile components • Coining on low-tonnage press helped with delivering assured flatness for 32 mm x 24 mm area • Processing conditions played a key role in getting the best flatness out of the furnace • Finally needed a grinding operation to assure compliance • Quality of thread (40UNS) on 21 mm ID • Geometry and quality would not allow molded-in threads • Machined in-house on CNC

  5. MIM Case Study - Housing • Economics • Needed a 4 Cavity tool for production rates and cost • The key to success was efficiency in secondary operations • Conclusion • Good application for MIM!

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