Abstract
STUDY GOAL AND OBJECTIVES
BCC' s goal in conducting this study is to analyze the current status of the
ceramic and metal injection molding (MIM) technology and business. The report
covers both powder and liquid processes for metal injection molding. When
referring to ceramic and/or metal powder injection molding, the term powder
injection molding (PIM) is often used. The term thixo-molding is often used to
refer to liquid metal injection molding. All of the processes have the
injection molding machine in common, and are at times undertaken by the same
companies, which may also be plastic injection molders. The report is designed
to provide an overview of the current technology, new developments, business
opportunities, and an assessment of the markets. The goals of this report are
to:
- Provide an overview of ceramic and metal injection molding technology.
- Explain and forecast the rapid growth of Asian producers in the shifting
global marketplace
- Understand the current industry structure and future trends.
- Analyze the business for potential new developments and trends.
- Identify and analyze applications and markets for potential for growth of
this technology and business.
- Review and analyze the patents awarded over the past five years and assess
technological trends.
- Explain and forecast the economic pressures facing raw materials for these
industries.
- Describe the business problems facing the industry.
The study' s primary goal is to give readers a clear understanding of the
ceramic and metal injection technology and business and growth potential over
the next five years. BCC uses 2009 as the base year, since this report was
completed in late 2008. Data for 2009 are forecast based on estimated, full
2008 data. The knowledge of both the market and technological trends will help
companies prepare for future developments. The knowledge will be helpful in
improving business strategies for growth and success in the marketplace.
REASON FOR DOING THE STUDY
Ceramic and metal injection molding is a near net shape manufacturing
technology that is extremely cost effective in producing small complex parts.
The technology is growing in importance as design engineers develop new
components that require greater mechanical strength than offered by synthetic
materials. Concurrently, there is a trend toward miniaturization. At the same
time, there is an enormous drive to reduce costs. This has a two-pronged
effect on ceramic and metal injection molding: 1) New designs combine
functionality or eliminate processing steps, requiring a more complex design
that can only be achieved through injection molding; 2) There are drives to
boost scale, thus making injection molding a more attractive economic option
than competing processes such as machining. Metal injection molding also has
environmental advantages over casting, while also reducing energy costs.
Reasons for doing the study (Continued) Meanwhile, the technologies are vastly
improving, particularly in the area of powder size. Better simulation and
control systems are being commercialized for injection molding machines
processing materials other than plastics. New furnaces also improve economies
of scale for big-ticket markets, such as automotive. New standards have also
opened bigger markets for ceramic and injection molding, which only started to
become an important commercial industry in the last 15 years. The technology
is being used to manufacture parts and components for the aerospace,
automotive, electronics, telecommunications, consumer, medical, and dental
industries.
When MIM technology was developed, there was significant excitement in the
industry. Very high growth rates were projected and a significant number of
companies came into being to utilize this technology. While initial
projections were overblown, the industry has grown significantly. Growth rates
slowed some in the 2006 to 2008 period because of soaring metals prices, a
slowing auto market, and spotty economic conditions globally. BCC forecasts
the industry is due for another growth spurt.
This is the first and only study to include ceramic and metal as powder
injection molding, and to include thixo-molding for liquid metals, such as
magnesium and aluminum. This is important because these parts are all made on
the same equipment and compete in the same markets - sometimes even for the
same parts. Any report that fails to include all three processes is inadequate.
BCC also is issuing this report because of significant changes taking place in
the global industry structure. Powder injection molding was invented in the
United States in the early 1970s by two engineers named Karl Zueger and
Raymond E. Wiech, Jr. The United States had a strong lead, with Europe and
Japan quickly following. Now the growth is shifting to China and other Asian
countries. This report defines the trend and its impact on existing companies
in the business.
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