Metal Injection Molding

Report Highlights

REPORT HIGHLIGHTSS

• The global metal injection molding market will expand at an average annual growth rate (AAGR) of 8.4% from $382 million in 2004 to a healthy $571 million by 2009.
• The market in Japan is the fastest growing, at an AAGR of 10.6%, and is expected to reach $185 million by 2009.
• The U.S. market is the largest, but will grow more slowly at an AAGR of 7.2% to $240 million by 2009.
• The rest of Asia (includes China) and European markets will both rise at AAGRs of 7.9% to $35 million and $111 million, respectively.

INTRODUCTION

Metal injection molding is a near net shape manufacturing technology that is extremely cost effective for producing small complex parts. For this reason, combined with beneficial use of metals and alloys that lead to less waste, efficient energy use and positive environmental impacts, this manufacturing technology should be of prime interest to the metal forming industry. The technology can be used to overcome drawbacks associated with conventional casting and machining techniques. It allows redesign of multiple components into a single part and simplifies manufacturing processes.

Because of an ability to make high-density parts with very close tolerance limits and excellent surface quality, metal injection molding technology has a wide range of applications. It has been used to manufacture parts and components for the aerospace, automotive, electronics, telecommunications, consumer, medical and dental industries.

This BCC study reviews the current industry structure, its competitive environment, and forecasts its growth potential. The report also reviews and analyzes steps in the manufacturing process for technology developments and trends.

SCOPE OF STUDY

The report contains:

• A concise review of the manufacturing technology, identifying current status and new developments, including the advent of nanopowders
• Coverage of North American and leading overseas firms that manufacture powder metals and those that manufacture parts using metal injection molding technology
• Five-year projections for the broad range of markets and applications that are served by metal injection molding technology, with forecasts through 2009
• Full coverage of metal powders and MIM parts made from iron and steel, stainless steel, copper, aluminum, molybdenum, tungsten, tungsten carbide, nickel, and tin
• A thorough review and analysis of the industry's structure as well as global competition.

METHODOLOGY

A careful methodology was followed to generate all the information related to the current status of the industry. The first step focused on identification of the companies using metal injection molding to produce parts and components. The metal powders, binder systems, equipment needs and markets were reviewed and researched. The information was generated for many, many MIM companies in Asia, Europe, Australia and North America. Almost all companies that are listed in the report were contacted to gather the data and gain their perspectives on the industry. The information was reviewed and analyzed to estimate relevant statistics such as market size and market shares.

Also, forecasts for each market segment were generated. This included analyzing the growth of the U.S. economy and global economy as well as growth of the industries during the forecast period. A wide spectrum of resources was used to understand and analyze the current state of the industry and potential for future growth.

INFORMATION SOURCES

A variety of information sources were used to gather the information used to compile this study. Some of the main sources include:

• The manufacturing companies currently using metal injection molding technology to serve a wide variety of markets.
• The equipment suppliers as well as suppliers of binders and feedstock to the manufacturing companies.
• Technical reports, product literature and press reports on metal injection molding technology, the powder metallurgy industry, and the end users of MIM components and parts.
• Trade publications (American Metal Market, the International Journal of Powder Metallurgy, Metal Powder Report, Machine Design, and Injection Molding Magazine) and some interviews with industry participants.
• Statistics and literature from the Metal Powder Industries Federation, the Japan Powder Metallurgy Association, and the European Powder Metallurgy Association.
• Government publications such as U.S. Industrial Outlook, Department of Commerce Studies, and U.S. Census reports on conditions.
• Sales and marketing data from Dun & Bradstreet, the Thomas Register, websites of the relevant companies and research institutions, selected firms in the industry and correspondence with willing executives and personnel in the industry.
• The U.S. Patent Bibliographic Database from the U.S. Patent and Trademark Office and company product brochures, annual reports, and other literature.

ANALYSTS CREDENTIALS

Balaji (Bal) V. Patil received his Bachelor of Technology degree in Metallurgical Engineering from the Indian Institute of Technology in Mumbai, India. He came to the United States for studies at Columbia University, New York City, NY where he completed his Master of Science degree in Mineral Engineering and Doctor of Engineering Science degree in Chemical Metallurgy. After a brief employment period with Cities Service Company, Dr. Patil joined Allegheny Ludlum Steel Corporation in 1976. He worked at the company's R&D Center and made significant technical contributions. Dr. Patil received five Corporate Technical Awards, has three patents and several technical publications. He also lead-authored a chapter in "The Making, Shaping and Treating of Steel: Steelmaking and Refining", 11th Edition, which was published by the AISE Foundation.