MPIF’s PM Design Excellence Awards 2025: Celebrating innovation in Metal Injection Moulding

Metal Injection Moulding has become a defining thread in the MPIF’s annual PM Design Excellence Awards, with components produced by the technology showcasing its strengths in high-volume, precision manufacturing across diverse industries. In 2025, award-winning parts highlight MIM’s particular advantages: tight dimensional control, thin-wall capability, and near-net-shape efficiency that reduces both machining and material waste. The winners also highlight a trend towards significantly larger parts than traditionally associated with the process.

Notable examples include precision frames for LiDAR sensing, large and durable pistol components, high-conductivity copper housings for thermal management, and intricate multi-component medical assemblies delivered with repeatable fit and finish. Collectively, the winners reaffirm MIM as a production-ready route within PM, and a complementary process to sinter-based Additive Manufacturing – where design freedom meets disciplined process control at industrial scale.

Grand Prize Awards

Automotive – electric vehicle

China’s Hangzhou Sino-MIM Technology Co Ltd also secured a Grand Prize for a MIM 316L stainless steel grounding diaphragm bracket (Fig. 2) that supports structural parts for optical lenses inside an automotive Light Detection and Ranging (LiDAR) unit. This part requires edge chamfering, as well as high dimensional accuracy and flatness specifications. Insights from this development supported further advancements in similar frame-structured parts.

Military/firearms

ARC Group Worldwide, headquartered in the US, won a Grand Prize for a pistol slide (Fig. 3) that encapsulates the barrel of the pistol and pushes the hammer back into the ready-to-fire position after each shot. The part passed a 20,000-shot trial firing test, with interim X-ray inspections. MIM allows features like ribs and logos to be moulded in, greatly reducing machining waste compared to forged blanks.

Electronic/electrical components

Hangzhou Sino-MIM Technology Co Ltd earned a Grand Prize for a copper alloy optical module housing used for efficient heat dissipation (Fig. 4). The part is made from a proprietary copper-based alloy and has strict requirements for surface flatness and roughness. Secondary CNC machining is required. Compared with machining from wrought or cast material, MIM offers over 55% cost savings.

The second Grand Prize in this category went to 3DEO, Inc, USA, for a copper heat sink used in semiconductor manufacturing (Fig. 5). The heat sink’s complex lattice design was developed in conjunction with the customer to maximise heat transfer efficiency while maintaining compatibility with Additive Manufacturing. The design is entirely self-supported during manufacturing, meaning it requires no build supports, and is optimised for automated de-powdering. This critical component is HIP processed to achieve 99.9% relative density, which is critical for pure copper applications.

Hand tools/recreation

ARC Group Worldwide was also awarded a Grand Prize for a knife blade used in a consumer pocketknife (Fig. 6). The blade had to achieve a hardness of 60 HRC or greater, impact toughness comparable to machined billet, and excellent straightness. A high-carbon alloy steel was used in the MIM process to mould the hollow grind blade geometry as-moulded, eliminating complex grinding and machining steps. MIM also significantly reduces material waste.

Hardware/appliances

INDO-MIM, USA/India, received a Grand Prize for pocket and keeper module parts for caravan door hinges (Fig. 7). Made from a niobium-stabilised austenitic chromium-nickel stainless steel, these parts secure hinge pins in place and ensure long-lasting performance. Compared with casting, MIM offers faster production, fewer manufacturing steps, and substantial cost savings.

Medical/dental

An A-to-Z expander assembly used in dental orthodontic treatment and sleep apnoea therapy earned INDO-MIM another Grand Prize (Fig. 8). The expander widens a narrow palatal arch and promotes nasal cavity expansion, aiding airflow. Seven intricate stainless steel MIM parts are assembled to create the expander. MIM simplifies the production process and reduces waste.

Awards of Distinction

Automotive – chassis

INDO-MIM also received recognition for a complex ASV top plate in vehicle suspension, featuring thirty narrow through slots and internal ribs (Fig. 9). MIM replaced prior machining and wire cutting, saving 40% in cost.

Military/firearms

Advanced Powder Products, Inc (APP), USA, earned an Award of Distinction for a pistol sear housing block (Fig. 10). The component includes multiple precision holes and thin functional walls. X-ray inspection verified defect-free quality. CNC machining was not cost-effective at scale.

Medical/dental

Hangzhou Sino-MIM Technology was recognised for an endoscopic stapler anvil used for surgical tissue resection and anastomosis (Fig. 11). Made from stainless steel and nickel-Teflon plated, the MIM part meets biocompatibility standards and replaces complex machined parts, cutting costs by 50%.

Electronic/electrical components

Hangzhou Sino-MIM Technology also took home an award for an AlN heatsink used in silicon photonics optical modules (Fig. 12). The brittle aluminium nitride part acts as both a heat sink and a mounting substrate. Flatness and parallelism tolerances are stringent.

The company also received recognition for a MIM-17-4 PH stainless steel middle plate used in a foldable mobile phone hinge (Fig. 13). The 0.3 mm-thick part connects mechanical devices and is made using high-precision processing.

Hand tools/recreation

Nichols Portland Inc., NPI–MIM/MAM Division, earned an award for a banjo capo assembly for Paige Musical Products (Fig. 14). The two stainless steel AM parts are used in their as-manufactured condition and deliver a 50% cost saving over machined equivalents.

Further information

Awards were presented during the PowderMet2025 conference, which took place June 15–18 in Phoenix, Arizona, USA.

Further information on PM technology, including all past MPIF Design Excellence Award Winners, is available from www.mpif.org.