Avoiding Common Metal Injection Molding Problems

Metal injection molding (MIM) is a highly versatile manufacturing process that enables the production of complex and geometrically-challenging metal parts with a high degree of accuracy and consistency. MIM is commonly used in various industries, including automotive, aerospace, medical, and consumer electronics. However, like any manufacturing process, MIM is not immune to its own set of problems and challenges. In this blog post, we will discuss some of the most common metal injection molding problems and how to avoid them.

Poor feedstock quality

Feedstock is a critical component in the MIM process, as it directly affects the quality and performance of the final product. Poor feedstock quality can result in various defects and flaws, such as porosity, cracking, voids, and uneven shrinkage. To avoid feedstock-related problems, it is essential to use high-quality powders that have consistent particle size distribution, low gas content, and minimal contamination. Additionally, the feedstock must be properly mixed, dried, and granulated before being fed into the MIM machine.

Inadequate mold design and maintenance

Mold design is another crucial aspect of the MIM process that can significantly impact the quality and efficiency of the production. A poorly designed or maintained mold can result in various defects, such as warpage, flashing, gate vestige, and injection pressure loss. To avoid mold-related problems, it is advisable to work with experienced mold designers who can optimize the gating, venting, cooling, and ejection features of the mold. It is also essential to perform regular maintenance and cleaning of the mold to prevent wear, corrosion, and accumulation of debris.

Insufficient process control and monitoring

MIM is a highly controlled process that involves multiple variables, such as temperature, pressure, flow rate, and cooling rate. Any deviation from the optimal process parameters can lead to defects and problems, such as underfill, overpacking, burnout, and dimensional errors. To avoid process-related problems, it is necessary to establish a robust process control and monitoring system that can measure, record, and analyze the critical process variables in real-time. This system should also have the flexibility to adjust the parameters to account for normal variations and unexpected events.

Lack of operator training and expertise

MIM is a complex and sophisticated process that requires a high level of skill and knowledge from the operators and technicians. A poorly trained or inexperienced operator can make critical mistakes that can compromise the quality and consistency of the parts. To avoid human-related problems, it is crucial to invest in comprehensive operator training and education programs that cover all aspects of the MIM process, including safety, quality control, troubleshooting, and maintenance.


In summary, metal injection molding is a versatile and efficient process for producing complex metal parts. However, it is not immune to its own set of problems and challenges. By addressing the common metal injection molding problems mentioned in this article, you can enhance the quality, efficiency, and profitability of your MIM operation. Remember, prevention is always better than correction, so invest time, resources, and expertise in ensuring that your MIM process is optimized and streamlined for success.

metal injection molding problems

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Sigma Technik Limited's rapid injection molding service injects molten plastic materials into molds using injection molding machines and molds, and cools and solidifies them over a certain period of time, ultimately forming the required plastic parts. This manufacturing process is usually suitable for producing small and medium-sized plastic parts, which can obtain high-quality and precise parts in a short period of time.

Plastic Injection Molding

Injection molding is a common manufacturing process to produce low volume to large volumes of parts typically made out of plastic. The process involves injecting molten material into a mold and letting it cool to a solid-state.

Liquid Silicone Rubber Molding

Liquid Silicone Rubber is known as LSR, which is a process used to produce parts made from silicone rubber, widely used create products such as medical devices, automotive parts, baby care products, and many others.

2K Injection molding

2K injection molding is a manufacturing process in which two different types of plastic materials are molded together in a single operation to create a single homogeneous component. This process allows for efficient and cost-effective production of high-quality parts that can perform unique functions.

Overmolding and Insert Molding

Overmolding / Insert molding combines two or more materials into a single part, one of the material is usually soft and flexible, or metal. The purpose of overmolding/insert molding is to add functionality, improve grip, provide protection, or enhance aesthetics.

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ABS is a type of plastic with high strength, hardness, and toughness. It has good impact resistance and wear resistance, and is suitable for manufacturing shells, components, and models.


PC is a transparent, high-strength, high-temperature resistant, and excellent electrical insulation material. It is suitable for manufacturing transparent components, electronic components, and automotive components.


PP is a relatively flexible material with excellent corrosion resistance and high temperature resistance. It is suitable for manufacturing containers, pipelines, baby bottles, etc.


PA is a material with high strength, high rigidity, and wear resistance. It is suitable for manufacturing gears, bearings, brackets, etc.


POM is a material with excellent wear resistance, toughness, and rigidity. It is suitable for manufacturing gears, bearings, pulleys, etc.


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Rapid Injection Molding FAQs

Burrs appear on the surface of the product, which affects its aesthetics and safety. The solution can be to adjust the parameters of the injection molding machine, such as temperature, pressure, speed, etc., or to perform post-processing, such as polishing, sandblasting, etc.

The warping deformation of the product is usually caused by unstable parameters such as temperature and pressure of the injection molding machine, or improper mold design. The solution can be to adjust parameters such as temperature and pressure, or to redesign the mold.

The occurrence of bubbles inside the product may be due to the high temperature of the injection molding machine and the high moisture content of the material. The solution can be to reduce the temperature of the injection molding machine, adjust the water content of the material, increase the pressure of the injection molding machine, etc.

The product size deviation is too large, which may be caused by material thermal expansion, mold deformation and other reasons. The solution can be to adjust parameters and optimize mold design based on material characteristics.