Table of Contents
This article examines how Indo MIM Revolutionizes Tool Insert Production with Binder-Jet 3D Printing. For over a decade, the manufacturing world has relied on Laser Powder Bed Fusion (LPBF) 3D printing to produce tool inserts. Despite its widespread use, the LPBF process is often criticized for its slow speed and limited material options, particularly in the production of tool inserts where only Maraging Steel is offered. Even post-heat treatment, Maraging Steel can achieve a maximum hardness of 55 HRC, rendering it less favorable for numerous tooling applications.
Introduction of Binder-Jet 3D Printing by Indo MIM
In a groundbreaking development, Indo MIM has introduced a new era in tool insert production with the adoption of Binder-Jet 3D printing. This innovative process boasts a printing speed approximately five times faster than the LPBF method. Notably, Indo MIM has developed a Tool Steel M2 grade material specifically for Binder-Jet 3D printing, marking a significant advancement in the field.
Binder-Jet 3D Printing is a process in which an industrial printhead selectively deposits a liquid binding agent onto a thin layer of powder particles — foundry sand, ceramics, metal or composites — to build high-value and one-of-a-kind parts and tooling. Similar to printing on sheets of paper, the process is repeated layer by layer, using a map from a
digital design file, until the object is complete.
Since mid-2022, Indo MIM has been successfully printing tool inserts using this cutting-edge technology. Currently, more than 800 mold inserts for Metal Injection Molding (MIM) are actively used in production. This milestone is a testament to Indo MIM’s extensive expertise in material development and sintering, honed over a span of 25 years.
Development of Tool Steel M2 for Binder-Jet 3D Printing
The M2 grade material developed by Indo MIM offers remarkable advantages over conventional wrought M2 material. It exhibits a 50% to 80% increase in wear resistance and a 40% improvement in machinability. These enhancements are achieved through a finer grain microstructure and a minimum density of 99% post-sintering. The consistent hardness of 63 to 66 HRC further underscores the superior quality of Indo MIM’s M2 material.
One of the standout features of Binder-Jet 3D printing is its unparalleled design freedom, allowing for 360-degree customization. Indo MIM can produce tool inserts ranging from 300 grams to 8 kilograms, achieving near-net shapes with remarkable precision.
This innovation by Indo MIM not only addresses the limitations of the LPBF process but also sets a new benchmark in the manufacturing industry. The introduction of Binder-Jet 3D printing for tool inserts signifies a major leap forward, promising faster production times, improved material properties, and unprecedented design flexibility.
Material properties at a glance
Recently, Indo-MIM has announced a strategy partnership with HP Inc. to mass-produce metal 3D-printed parts in India. This collaboration aligns with the ‘Make in India’ initiative and aims to revolutionize metal parts production for sectors such as automotive, aerospace, defense, consumer electronics, and medical equipment.
As part of the collaboration, INDO-MIM has invested in three HP Metal Jet S100 printers. Two printers will provide localized support for Indian clients and expand production capabilities. One will focus on new material development, while the other will drive application development, catering to customers in India, the Middle East, and the Asia-Pacific region.
“The acquisition of HP’s Metal Jet S100 printers equips us with the latest technology, enabling us to meet the growing demands of our customers with efficiency and precision, as well as expand the library of materials qualified on the HP printer platform”, stated Krishna Chivukula Jr., CEO of INDO-MIM.
About Indo MIM
Indo MIM is a global leader in metal injection molding and precision manufacturing, renowned for its commitment to innovation and excellence. With over 25 years of expertise in material development and sintering, Indo MIM continues to push the boundaries of manufacturing technology, delivering high-quality solutions to meet the evolving needs of various industries.
