Metal Injection Molding Services

Yes. Metal injection molding blends fine metal powder with a thermoplastic binder to create a feedstock, which is injected into a precision mold. The binder is then removed through debinding, and the part is sintered to achieve full metal density. The result is a complex, high-strength metal part that would be slow or costly to machine.

Fine metal powder is blended with a binder to create a feedstock. The feedstock is injected into a mold cavity to form a green part. The binder is removed through thermal or chemical debinding, and the part is then sintered at high temperature to densify to near-solid metal. Secondary operations such as machining, heat treatment, or plating follow as required.

MIM produces small, complex metal parts at lower per-unit cost than machining and faster than investment casting, with near-net-shape output that reduces waste. The main trade-off is high upfront tooling cost, which makes the process best suited to high annual volumes. Part size is also limited: as parts get larger, cost rises quickly.

Both inject material into a die, but die casting uses molten aluminum or zinc while MIM uses a powdered steel feedstock. MIM can hold finer geometries and uses a wider range of steel alloys. Die casting suits larger, non-ferrous parts at very high cycle rates. Our engineering team can help you determine which process fits your part.

We run low alloy steels and stainless steels as the core MIM materials. Additional MIM-compatible alloys are reviewed at the feasibility stage based on your part's mechanical and corrosion requirements.

Standard production lead time is 4 to 8 weeks, with tooling and first-article timing confirmed at the quote stage. Rush programs can be reviewed case by case.

MIM holds tight tolerances on small, complex metal parts, with final tolerances confirmed against your drawing at the feasibility review. The process favors small and miniature components: as parts get larger, feedstock and sintering cost rise quickly, so bigger geometries are usually better suited to casting or machining.

Yes. Sintered low alloy and stainless steel parts can be heat treated to raise hardness and strength, and finished with plating, passivation, or black oxide. Our engineering team matches the secondary operations to your part's mechanical and corrosion requirements.

MIM is the best fit for small, strong, high-repeatability parts that would otherwise be machined from bar stock. The three main decision variables are material, geometry complexity, and volume. If your part requires iron or a ferrous alloy with a detailed shape, investment casting may work, but MIM often delivers better dimensional accuracy at a lower per-part cost once tooling is built. For aluminum with complex geometry, die casting is typically the answer. Real process selection is a conversation, not a lookup table.

Inconsistent wall thickness is the most common issue. Non-uniform walls cause uneven fill and cooling during thermal processing, leading to warpage, sink marks, and porosity. Another frequent mistake is specifying tolerances tighter than the process can reliably hold, which forces secondary operations that add cost and lead time. Redstone's DFM review catches these issues before tooling begins and recommends geometry changes that improve part quality while reducing production cost.

Redstone identifies critical-to-quality (CTQ) dimensions from your print and end-use application. Every callout is ballooned into an inspection template, including notes, material, and title block. A second pass layers in experience from past quality issues and mating-part fit. Critical dimensions are inspected with CMM, and process capability is validated so that interval-based checks replace 100% inspection once the process is confirmed stable. Embedded staff at each facility check production daily.

Redstone catches issues before parts ship and does not rely on the customer to find them. If something does fail inspection, the response follows a structured process: 100% sort of the affected lot, containment of nonconforming inventory, root cause analysis, and corrective action. Redstone guarantees parts and will repair, replace, or refund. Replacement parts are air-shipped when rework is not possible, and every corrective action is audited to confirm it holds.