In 2020, our company reviewed precision component drawings provided by a U.S. client with whom we had collaborated for three years. The client’s original plan was to adopt 5-axis CNC machining for mass production.
After conducting a comprehensive process evaluation—covering product structure, performance requirements, and mass production economics—our engineering team proposed an optimized solution: replacing conventional machining with Metal Injection Molding (MIM). The key advantages were as follows:
1. Significant weight reduction: The weight per unit was reduced to approximately 90g, only one-quarter of that of the original machined part.
2. Superior near-net-shape capability: MIM offers enhanced formability and precision for complex, thin-walled structures.
3. Improved material utilization and efficiency: Substantially higher material utilization, significantly reduced defect rates, improved scalability for mass production, and a considerable reduction in overall manufacturing costs.
The client maintained a cautious stance regarding the stability and forming quality of the MIM process and initially insisted on retaining the original machining-based design.
Following technical discussions, the client placed a pilot order of 5,000 units. We first completed and delivered 2,000 machined parts for assembly validation. However, these parts failed to meet assembly requirements due to excessive weight.
After assembly verification, the client promptly decided to convert the remaining 3,000 units to the MIM process. Within three working days, the client paid 70% of the MIM tooling development cost, enabling rapid project launch and implementation. (The attached image shows semi-finished scrap generated from the original machining process.)
Through pilot-scale validation, the client was able to confirm process feasibility with minimal risk. Ultimately, the adoption of MIM enabled lightweight, thin-walled, and cost-effective mass production, fully meeting assembly and volume production requirements.
