The MPIF’s 2023 PM Design Excellence Awards saw ten Grand Prizes and fifteen Awards of Distinction presented to winners across three process categories: conventional press and sinter Powder Metallurgy, metal Additive Manufacturing and Metal Injection Moulding. The winners are excellent examples of the diversity of PM, ranging from applications in vehicles to medical devices and electronics. They were praised by the judges for being able to meet critical requirements while competing with other technologies.

In this report, we highlight the winning parts produced by MIM and metal Additive Manufacturing. A large number of award winning parts produced by ‘press and sinter’ PM are covered in the Autumn 2023 issue of PM Review, available to download from www.pm-review.com.

Grand Prizes

Hand Tools/Recreation

Indo-MIM Pvt Ltd.

A Grand Prize was awarded to Indo-MIM Pvt Ltd., Bengaluru, India, and San Antonio, Texas, USA, in the Hand Tools/Recreation category for a MIM 17-4 PH stainless steel component for a keeper release used in a sub-assembly for safety door locks (Fig. 1). This 60 mm long part has a square central cross-section with rectangular blocks at each end as well as a ‘h’ shaped projection part way along the central section. The part is moulded in a multi-cavity tool in which a side core covers the ‘h’ profile and another side core from one end covers the hole profile. The part is used in safety door locks and needs to withstand frictional forces and wear and tear.

Electronic/Electrical Components

Hangzhou Sino-MIM Technology Co. Ltd.

Within the Electronic/Electrical Components category for MIM components, a Grand Prize was awarded to Hangzhou Sino-MIM Technology Co. Ltd., Hangzhou, China, for a heatsink used in an optical communication 5G base station photoelectric module bracket for heat dissipation (Fig. 2). The part is made from a tungsten-copper (W-Cu 80/20) duplex pseudo alloy. The feed material is a nano-grade metal powder, so the mould requirements are very high. The design has one mould with two cavities. The product was previously made using copper-infiltrated tungsten processed using CNC and wire EDM, a complex and expensive process. MIM processing reduced part cost by more than 45% and the production cycle time was shortened.

Hardware/Appliances

Hangzhou Sino-MIM Technology Co. Ltd

Hangzhou Sino-MIM Technology Co. Ltd. was awarded a second Grand Prize, this time in the Hardware/Appliances category, for MIM components for a screw used in a juice maker (Fig. 3). The part was originally designed as a plastic injection moulded component that was easily deformed and had poor wear resistance. This led to 304L stainless steel being suggested as an alternative. However, the metallic part weighed nearly 860 g, which was not ideal. The component was, therefore, divided into several small parts and a structure created with a hollow interior which reduced the part mass to 470 g, a 45% reduction. The conversion from plastic to a MIM part has led to a better surface finish and mechanical properties, and a significant improvement in the lifetime of the product.

Industrial Motors/Controls / Hydraulics

Azoth

A Grand Prize in the Industrial Motors/Controls & Hydraulics category for metal AM components was awarded to Azoth, Ann Arbor, Michigan, USA, for a fluid matter exchanger (Fig. 4). While relatively simple in appearance on the outside, the part is extremely complex on the inside.

The part is produced by Binder Jetting (BJT) using 316L stainless steel powder. The as-built part is about 20% larger to account for shrinkage during sintering. The customer performs flowability as well as pressurised leak testing of the parts. The hollowness, internal channels, internal filters, and other complex features of this fluid matter exchanger make it a part only viable through Additive Manufacturing.

Medical/Dental

Hangzhou Sino-MIM Technology Co. Ltd.

In the Medical/Dental category for MIM components, a third Grand Prize was awarded to Hangzhou Sino-MIM Technology Co. Ltd., for a titanium alloy kneecap part used to repair or replace a human kneecap (Fig. 5). The part is made using a titanium alloy (Ti-6Al-4V) and weighs about 74 g. The surface is polished to a mirror finish. Traditional kneecaps are made from stainless steel, which is heavy and has lower surface wear resistance. Traditional kneecaps are made using CNC machining, with long lead times and high costs. MIM production reduced costs by about 50% and the titanium alloy part has good biocompatibity and is much lighter.

Medical/Dental

3DEO Inc.

In the Medical/Dental category for metal AM components, a Grand Prize was awarded to 3DEO Inc, Torrance, California, USA, and its customer, USB Medical, for a surgical implement articulation joint and pivot. The assembly is part of a surgical implement for performing laparoscopic heart surgery. The instrument is used to lift the heart gently, granting the surgeon access to the back of the heart. The three-part assembly (Fig. 6) is produced from 17-4 PH stainless steel using 3DEO’s layering process, in which 100 µm layers of powder are deposited, uniformly bonded edge-to-edge, and machined on a per-layer basis until the parts are fully built. Demand volume does not warrant MIM tooling investment, and metal AM retains the customer’s ability to make future design changes.

Military/Firearms

TriTech Titanium Parts LLC

In the Military/Firearms category for MIM components, a Grand Prize was awarded to TriTech Titanium Parts LLC, Detroit, Michigan, USA, for a MIM titanium ring clamp used in a mounting device for a rifle magnifying scope (Fig. 7). The finished assembly includes two ring clamps attached to a cantilever mount, that is secured to the rifle with two quick disconnects. Each ring clamp is made of two parts and features an inner ring and an outer cage.

The entire finished assembly is coated flat black with a thin-film protective ceramic coating by the customer. The titanium alloy (Ti-6Al-4V) ring clamp assembly replaces a heavier machined 6061 aluminium alloy version. To receive final approval, the assembly had to protect the scope after repeated drop testing. This titanium alloy part has four times the tensile and yield strength of the commonly used aluminium alloy.

Awards of Distinction

Automotive – Engine

Hangzhou SINO-MIM Technology Co. Ltd.

In the Automotive – Engine category for MIM components, an Award of Distinction was given to Hangzhou Sino-MIM Technology Co. Ltd. for a turbocharger nozzle ring assembly, an application that requires good strength, oxidation, and corrosion resistance at high temperatures. The parts had previously been made using a precision casting process that has lower production efficiency, poor dimensional accuracy, poor surface finish, and more secondary machining than MIM parts require. With MIM, only the vane nozzle needs post-process machining.

Automotive – Chassis

Indo-MIM Pvt Ltd.

Indo-MIM Pvt Ltd. received an Award of Distinction in the Automotive – Chassis category for MIM components for right- and left-hand thread inserts made from MIM-4605 low-alloy steel (quenched & tempered) and used in collapsible roof systems to clamp and hinge different components of the system (Fig. 9). The parts are made in a two-cavity hot runner mould. The optimum injection point is critical due to the varied sectional thicknesses and was determined via mould flow simulation. Thread auto unwinding was a major challenge for the tooling. Powder coating and electroplating enable the parts to satisfy a 2,000-hour salt spray test.

Hand Tools/Recreation

Indo-MIM Pvt Ltd.

In the Hand Tools/Recreation category for MIM PM components, an Award of Distinction was also given to Indo-MIM Pvt Ltd. for a clamp body used in a sub-assembly for hand power tools (Fig. 10). The part is U-shaped with a single boss on one leg, with three bosses and two pin-like projections on the opposite leg. An innovative and effective way of cooling and venting helped to prevent voids and weld lines. The 4605 low-alloy steel part resulted in a cost saving of 60% compared with the machined part that it replaced.

Hardware/Appliances

3DEO Inc. and Narita Manufacturing

An Award of Distinction was also given to 3DEO Inc, and customer Narita Manufacturing, in the Hardware/Appliances category for metal AM components for a fastener assembly for a bullet train (Fig. 11). 3DEO uses what it calls Intelligent Layering technology, a patented sinter-based metal AM process that leverages precision machining of parts in the ‘green’ state.

The fastener attaches the inter-car baffles to retaining frames on bullet trains. The 17-4 PH stainless steel metal AM assembly replaced ten individual components and four rivets, eliminating riveting, welding, and grinding from the production process. The parts must be able to be rotated with a tool but be tamper-resistant to passengers and resist unintended rotation due to train car motion and vibration.

Industrial Motors/Control & Hydraulics

MPP and Schilling Robotics, a Technip FMC Company

In the Industrial Motors/Controls & Hydraulics category for MIM components MPP, Noblesville, Indiana, USA, and its customer Schilling Robotics, a Technip FMC Company, were awarded an Award of Distinction for a latch assembly used for the Seanet cable product (Fig. 12). This four-part (five-piece) assembly of MIM parts comprises latches and the latch tightening mechanism for a specialised electrical and communications cable used in the harsh environment of the deep ocean. Previously made from plastic, conversion to MIM-316L stainless steel was selected to resolve the problem of stretching and cracking. A low-friction, highly corrosion resistant coating is applied to the parts. A unique tooling approach reduced the customer’s tooling cost by 75%.

Medical/Dental

Advanced Powder Products Inc.

In the Medical/Dental category for MIM components, an Award of Distinction was given to Advanced Powder Products Inc. Philipsburg, Pennsylvania, USA, for lower anterior, upper central, bicuspid, and molar dental brackets (Fig. 13). The brackets are part of a newly introduced orthodontic correction procedure. The four single-piece brackets are made using custom micro MIM-17-4 PH feedstock. The original complex two-piece design had many issues for MIM processing. The solution was found in a single-piece design in which the dovetail depth and position was modified.

Military/Firearms

ARC Group Worldwide

ARC Group Worldwide, Denver, Colorado, USA, received two Awards of Distinction in the Military/Firearms category for MIM components the first of which was for an S-7 tool steel locking block housed within the lower receiver of a semi-automatic pistol for securing and stabilising movement of the slide and barrel (Fig. 14). The locking block is a critical component of a 9-mm semi-automatic pistol and provides stability and support of the slide and barrel during actuation. The part is housed within a polymer frame that utilises a single-action striker-fired trigger mechanism. MIM processing was selected for making this part because of the complexity, annual usage, and the existing presence in the firearms industry.

ARC Group Worldwide’s second Award of Distinction in the Military/Firearms category for MIM components was for a pistol slide stop (Fig. 15). Prior to MIM processing this part was assembled from multiple pieces or machined. The MIM process provides a single, net-shape part that does not require any machining. The slide stop is used on a modern pistol to hold the slide open when the magazine is empty, or the user needs to open the action.

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