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MIM Case Study – Contact

This case study focuses on using Metal Injection Molding (MIM) to improve a contact component for medical electronics, replacing a process involving stamped base and welded wire. MIM offers structural integrity, low thermal expansion, and cost savings, ensuring consistent quality and reliable connections. The MIM-Alloy 42 material with Ni & Au plating meets the functional requirements and enhances performance in high-volume applications.

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MIM Case Study – Contact

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  1. MIM Case Study – Contact • Application: Medical Electronics • Functional Requirements: Structurally intact; low thermal expansion • Competing Technology: Stamped flat base, welded wire for posts • Overall Size: • Base 0.25 mm thick, 1.25 mm square • Posts 0.5 mm diameter x 1.2 mm tall • Part Weight: 0.007 grams • Material: MIM-Alloy 42, subsequent Ni & Au plating

  2. MIM Case Study – Contact • Small Part! • MIM to replace existing process: • Base stamped out of gold-plated sheet • Posts made from wire form welded to base • - MIM seen as a cost savings with better consistency

  3. Key Characteristics- Contact One of two posts intact No cracks Minimal flash Posts strong enough to not deflect when wire is welded to posts; center support section added Parts needs to be solderable to the circuit board; bumps molded in to allow flow of solder under part

  4. MIM Case Study – Contact • Why MIM? • More consistent position of posts • Connection of the posts to the base is more reliable in a one-piece MIM part than the welded wire to the stamped base. • MIM Alloy 42 consistent with expected material properties • Economics of MIM regarding CAPEX, part price significantly better than stamp & weld • MIM a more repeatable for high-volume technology for this application

  5. MIM Case Study – Contact

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