Sinbo Precision Mechanical's Powder Metallurgy Production Breaks Through Complex Part Manufacturing Challenges
As the manufacturing industry advances towards high precision and complexity, powder metallurgy technology has become the key to solving the challenges of complex part manufacturing with its unique advantages. Sinbo Precision Mechanical's recent successful completion of a complex part production project for high - end medical devices is a powerful testament to its strong capabilities in the field of powder metallurgy production.
Project Background: Challenges Posed by Complex Requirements
An international renowned medical device company was developing a new surgical instrument. The core part featured complex structures such as multi - curved surfaces, thin walls, and high - precision hole systems, and it also had to meet strict performance requirements such as high strength and biocompatibility. Traditional processing techniques were not only difficult to form the part but also had low material utilization and high costs. After comprehensive evaluation, Sinbo Precision Mechanical was awarded the project due to its rich powder metallurgy production experience and technical reserves.
Technical Breakthrough: Innovative Processes Solve Problems
Customized Powder Preparation
To meet the part's biocompatibility and high - strength requirements, Sinbo Precision Mechanical used the gas atomization method to prepare medical - grade titanium alloy powder. By precisely controlling parameters such as atomization gas pressure, temperature, and metal liquid flow, the powder particle size was controlled between 15 - 45μm, ensuring a powder sphericity of over 98%. Meanwhile, the oxygen content was strictly controlled below 0.15%, laying the foundation for subsequent processes.
Multi - process Coordinated Forming
The combination of powder injection molding (PIM) and micro - injection molding techniques was adopted to overcome the challenges of complex structure forming. A precise combined mold was designed, and the gate position and runner design were optimized using mold flow analysis. The injection pressure was controlled at 120 - 150MPa, and the temperature was maintained at 180 - 200℃. This successfully achieved high - precision forming of the part's complex inner cavity and thin - wall structure, with a dimensional accuracy of ±0.03mm.
Gradient Sintering Optimization
In the vacuum sintering process, a gradient heating process was employed. The temperature was raised from room temperature to 600℃ at a rate of 5℃/min for debinding, then to 1250℃ at a rate of 3℃/min for solid - phase sintering, and finally held at 1350℃ for 2 hours for liquid - phase sintering. This process increased the part's density to 99.2% of the theoretical density, resulting in a uniform and fine internal structure with a tensile strength of 950MPa.
Project Results: Technical Strength Gains Recognition
After three months of research, development, and production, Sinbo Precision Mechanical successfully delivered the first batch of 1,000 parts. According to third - party testing, all parts met the design requirements, with a yield rate as high as 97%. The customer feedback indicated that the surgical instruments using these parts performed stably during actual operations, with their service life extended by 30%. This project not only solved the manufacturing problems for the customer but also enabled Sinbo Precision Mechanical to accumulate valuable experience in powder metallurgy production in the medical field, further consolidating its position in the industry.
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