Metal and Ceramic Injection Molding

Metal and Ceramic Injection Molding

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.

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.

INTENDED AUDIENCE

This report is extremely important to anyone currently in the metal or ceramic injection molding business: those who are considering entry to the market, investors in the marketplace, and those who will be strongly affected by the development of this sector. These groups are described below.

• Engineers and business managers who are looking for cost-effective solutions to vexing performance or cost problems in products they are currently developing.
  
  
• Engineers working for existing ceramic and metal injection molding companies. They can see how they stack up against the state-of-the art in design and manufacturing.
  
  
• Entrepreneurs who will be able to identify new areas for application of this technology and thus use it to start new businesses. Particularly important in this category are plastic injection molders in the United States and Europe who are taking a beating from low prices, Asian competition, and declining demand.
  
  
• The current manufacturers who use the PIM and thixo-molding manufacturing processes. They will understand the global nature of this business, the existing competition, the fluid nature of the industry structure as well as potential opportunities to use the technology to increase their PIM production and sales.
  
  
• The businesses that will be able to understand the current industry structure and competition so as to identify threats and opportunities. This information will be useful to anyone considering an investment in the industry.
  
  
• The report also provides information that would help a reader understand the MIM business and assist in evaluation of a new business plan, or evaluation of stock values of a publicly owned company that participates in the businesses such as BASF (BF on the New York Stock Exchange) or Precision Castparts (NYSE: PCP)..
  
  
• Other individuals will also find this report valuable. Scientists and academia will use it to understand the business and identify the areas for research and training of personnel to support the industry.

 
 

CHAPTER ONE: INTRODUCTION

STUDY GOAL AND OBJECTIVES

REASONS FOR DOING THE STUDY

REASONS FOR DOING THE STUDY (CONTINUED)

INTENDED AUDIENCE

SCOPE OF REPORT

SCOPE OF REPORT (CONTINUED)

INFORMATION SOURCES

ANALYST’S CREDENTIALS

RELATED BCC REPORTS

BCC ONLINE SERVICES

DISCLAIMER

CHAPTER TWO: EXECUTIVE SUMMARY

EXECUTIVE SUMMARY

SUMMARY TABLE 1 GLOBAL SALES OF MIM COMPONENTS (POWDER) BY REGION, THROUGH 2014 ($ MILLIONS)

SUMMARY FIGURE REGIONAL PERCENTAGE SHARE OF SALES OF MIM COMPONENTS, 2009 AND 2014 (%)

SUMMARY TABLE 2 GLOBAL SALES OF CIM COMPONENTS BY REGION, THROUGH 2014 ($ MILLIONS)

SUMMARY TABLE 3 LIQUID METAL MOLDING REVENUES BY REGION, THROUGH 2014

CHAPTER THREE: POWDER INJECTION MOLDINGINDUSTRY OVERVIEW

INTRODUCTION

THE PROCESS

POWDER PRODUCTION

FEEDSTOCK PREPARATION

INJECTION MOLDING

DEBINDING

SINTERING

DESIGNING FOR MIM

ADVANTAGES OF PIM

ADVANTAGES OF PIM (CONTINUED)

TABLE 1 ADVANTAGES OF POWDER INJECTION MOLDING

DISADAVANTAGES OF PIM

TABLE 2 DISADVANTAGES OF POWDER INJECTION MOLDING

PIM PRODUCT QUALITY

TABLE 3 COMPARISON OF METAL INJECTION MOLDING WITH SELECTED METAL FORMING TECHNOLOGIES

PIM PRODUCTS AND MARKET SECTORS

TABLE 4 METAL INJECTION MOLDED PRODUCTS BY MARKET SECTORS

CHAPTER FOUR: POWDER INJECTION MOLDING TECHNOLOGY

INTRODUCTION

DESIGN OF THE PART AND INJECTION MOLD

DESIGN OF THE PART AND … (CONTINUED)

METAL, CERAMIC AND ALLOY MATERIALS

ATOMIZATION (METALS)

TABLE 5 A COMPARISON OF WATER AND GAS ATOMIZATION PROCESSES

TABLE 5 (CONTINUED)

REDUCTION OF OXIDES (METALS)

CARBONYL DECOMPOSITION (METALS)

COMMINUTION (METALS)

OTHER METHODS FOR METALS

FINE GRINDING (CERAMICS)

CHEMICAL VAPOR DEPOSITION (CERAMICS)

BINDERS

SOLVENT DEBINDING

FEEDSTOCKS

TABLE 6 FEEDSTOCKS FOR PIM

TABLE 6 (CONTINUED)

INJECTION MOLDING

DEBINDING

SINTERING

SINTERING (CONTINUED)

CHAPTER FIVE: PIM INDUSTRY STRUCTURE

INTRODUCTION

POWDER AND FEEDSTOCK MANUFACTURERS

TABLE 7 MAJOR FIRMS SUPPLYING POWDERS AND FEEDSTCOKS TO THE MIM INDUSTRY

TABLE 7 (CONTINUED)

MIM PARTS AND COMPONENTS MANUFACTURERS

TABLE 8 MAJOR NORTH AMERICAN FIRMS MANUFACTURING PIM PARTS AND COMPONENTS

TABLE 8 (CONTINUED)

TABLE 9 MAJOR NON-U.S. FIRMS MANUFACTURING MIM PARTS AND COMPONENTS

TABLE 9 (CONTINUED)

SOLIDMICRON TECHNOLOGIES PTE. LTD., SINGAPORE

EQUIPMENT MANUFACTURERS

TABLE 10 MAJOR COMPANIES SUPPLYING EQUIPMENT TO THE PIM COMPONENT MANUFACTURERS

GLOBALIZATION

TABLE 11 PIM CAPACITY AND MARKET SIZE BY GEOGRAPHICAL REGION, 2009 ($ MILLIONS)

MIM INDUSTRY STRUCTURE

MARKET SIZE AND SHARES

TABLE 12 GLOBAL SALES OF PIM COMPONENTS BY REGION, THROUGH 2014 ($ MILLIONS)

FIGURE 1 GLOBAL SALES OF PIM COMPONENTS BY REGION, 2009 AND 2014 ($ MILLIONS)

TABLE 13 SALES AND MARKET SHARE OF MAJOR MIM COMPANIES IN THE NORTH AMERICAN MIM MARKET, 2009 ($ MILLIONS, %)

FIGURE 2 MARKET SHARE OF MAJOR COMPANIES IN THE NORTH AMERICAN MIM MARKET, 2009 (%)

TABLE 14 SALES AND MARKET SHARES OF MAJOR MIM COMPANIES IN THE JAPANESE MIM MARKET, 2009 ($ MILLIONS, %)

FIGURE 3 MARKET SHARE OF MAJOR COMPANIES IN THE JAPANESE MIM MARKET, 2009 (%)

TABLE 15 SALES AND MARKET SHARES OF MAJOR ASIAN MIM COMPANIES, EXCLUDING JAPAN, 2009 ($ MILLIONS, %)

TABLE 16 SALES AND MARKET SHARES OF MAJOR EUROPEAN MIM, 2009 ($ MILLIONS, %)

TABLE 17 GLOBAL SALES AND MARKET SHARES OF MAJOR MIM COMPANIES, 2009 ($ MILLIONS, %)

TABLE 17 (CONTINUED)

INDUSTRY ASSOCIATIONS

INDUSTRY ASSOCIATIONS (CONTINUED)

PIM RESEARCH LEADERS

PIM INDUSTRY STRUCTURE—SUMMARY

MIM INDUSTRY)

CHAPTER SIX: COMPETITIVE PROCESSES

CASTING

CONVENTIONAL POWDER METALLURGY

POWDER PRESSING

SOLID STATE SINTERING

CONTINUOUS POWDER PROCESSING

MACHINING

DIRECT MANUFACTURING

TRADITIONAL INJECTION MOLDING

LEAD REPLACEMENT

HEAVY COMPOUNDS

HYBRID PROCESSES

CHAPTER SEVEN: POWDER INJECTION MOLDING COMPANY PROFILES

ABBOTT FURNACE COMPANY

ACCELLENT INC.

ACELENT TECHNOLOGIES PTE LTD

ACUPOWDER INTERNATIONAL, LLC

ADVANCED CERAMETRICS, INC

ADVANCED MATERIALS TECHNOLOGIES PTE LTD

ADVANCED METALWORKING PRACTICES

ADVANCED POWDER PRODUCTS

ADVANCED TECHNOLOGY & MATERIALS CO.

ADVANTAGE METAL POWDERS, INC

AFFINITY INTERNATIONAL LLC (USA)

AG MATERIALS INC

AKRON PORCELAIN & PLASTICS CO.

ALBEROX, A DIVISION OF MORGAN ADVANCED CERAMICS, INC.

ALCOA HOWMET

ALD VACUUM TECHNOLOGIES AG

ALLIANCE SA

AMERICAN CHEMET CORP

AMERICAN ORTHODONTICS

AMETEK, INC.—SPECIALTY METAL PRODUCTS DIV

AMPAL, INC. (USB)

ARBURG GMBH CO KG

ARC SEIBERSDORF RESEARCH GMBH

ASBURY GRAPHITE MILLS, INC

ATC, INC

AVS, INC./ADVANCED VACUUM SYSTEMS

BASF CORP.

BASF EAST ASIA R. HQ LTD.

BASF AG

BONGEN TITANIUM CO., LTD

BRITT MANUFACTURING CO.

CABOT CORP.

CARPENTER POWDER PRODUCTS

CENTORR VACUUM INDUSTRIES

CERADYNE, INC.

CERAMET TECHNOLOGIES PTE LTD

CERAMCO, INC

C.I. HAYES

CENTER FOR INNOVATIVE SINTERED PRODUCTS

CERAMTEC NORTH AMERICA CORP.

CITIZEN WATCH CO.

CLARIANT PIGMENTS AND ADDITIVES DIVISION

CM FURNACES INC

CONTINUOUS METAL TECHNOLOGY, INC

COORSTEK

CORE-TECH, INC.

CPS TECHNOLOGIES CORP.

CREMER THERMOPROZESSANLAGEN GMBH

CYPRESS INDUSTRIES

DSH TECHNOLOGIES, LLC

DONCASTERS PRECISION CASTINGS

DOU YEE TECHNOLOGIES PTE LTD

DURON PLASTICS LTD

DYNAMIC ENGINEERING, INC

ECKA GRANULES OF AMERICA LP

EGIDE UK LTD

ELNIK SYSTEMS

EMIL BRÖLL GMBH & CO

ENGINEERED SINTERINGS & PLASTICS, INC.

EPSON ATMIX CORP

ETA SA MANUFACTURE HORLOGÈRE SUISSE

EVERSUN TECHNOLOGY CO., LTD

F.W. WINTER, INC. & CO

FLOMET LLC

FORM PHYSICS, LLC

FRAUNHOFER INSTITUTE

GKN SINTER METALS

GKN SINTER METALS GMBH (MIM)

GOCERAM AB

H.C. STARCK, INC

HERBERT KUGELE

HITACHI METALS AMERICA LTD.

HITACHI METALS LTD.—SPECIALTY STEEL COMPANY

HOEGANAES CORP

HOPTEC GROUPE FORSYM

INCO SPECIAL PRODUCTS

INDO-US MIM TEC PVT. LTD

INETI

INJECTAMAX CORP.

INSTITUT FÜR WERKZEUGMASCHINEN AND BETRIEBSTECHNIK

INTERNATIONAL SPECIALTY PRODUCTS (ISP)

ITB PRECISIETECHNIEK

KINETICS, INC.

KLÄGER SPRITZGUSS GMBH & CO

LATITUDE MANUFACTURING TECHNOLOGIES

LEISTRITZ CORP.

MATERIALS PROCESSING INC

MATHSON INDUSTRIES, INC

MAXON MOTOR AG

MEGAMET SOLID METALS, INC

METAL POWDER PRODUCTS CO

METAOR

MICROCERAM

MIMECRISA

MIMFLOW TECHNOLOGIES LLC

MIMFORMS LLC

MIMITALIA SRI

MKS KUNSTSTOFFSPRITZGUSS GMBH

MMG ENGINEERED COMPONENTS

MOMENTIVE PERFORMANCE MATERIALS INC

MORGAN TECHNICAL CERAMICS

NANOVAL GMBH & CO. KG

NEGRI BOSSI

NETSHAPE TECHNOLOGIES

NIPPON ATOMIZED METAL POWDERS CORP.

NOVAMET SPECIALTY PRODUCTS CORP.

OBE OHNMACHT & BAUMGARTNER GMBH & CO.

OM GROUP, INC

ONISHI LITE INDUSTRY CO., LTD.

ORTHO ORGANIZERS, INC.

PARMATECH CORP.

PCC-AFT.

PELTSMAN CORP.

PHILLIPS PLASTICS CORP.

PHILLIPS PLASTICS CORP. (CONTINUED)

POLYALLOYS INJECTED METALS

POLYMER TECHNOLOGIES, INC.

PORITE TAIWAN CO. LTD

PRECIMED S.A.

QUEBEC METAL POWDERS LTD

QINETQ NANOMATERIALS LTD

RAPIDUS USA, LLC

RAUSCHERT TECHNICAL CERAMICS

REMINGTON ARMS COMPANY, INC

RETCO TOOL CO

RIFMET LTD.

ROCKY MOUNTAIN ORTHODONTICS

RPM ENGINEERING CORP.

RYER, INC.

SAFFROSHINE ORGANICS PVT. LTD.

SANDVIK OSPREY LTD.

SCHUNK SINTERMETALLTECHNIK GMBH

SCM METAL PRODUCTS, INC.

SEMBACH GMBH & CO KG

SHANDONG JINZHU POWDER INJECTION MANUFACTURE CO.

SHANGHAI FUTURE HI-TECH CO., LTD

SINTER METAL TECHNOLOGIES

SINTEZ RUS MIM

SMALL PRECISION TOOLS

SMITH METAL PRODUCTS

SOLIDMICRON TECHNOLOGIES PTE. LTD

SSI TECHNOLOGIES, INC

SUN STAR INC

SUMITOMO METAL MINING CO., LTD

SUPERIOR TECHNICAL CERAMICS CORP.

TAISEI KOGYO CO., LTD.

TAIWAN SINTERED METALS CO. LTD.

TEIBOW CO., LTD.

THERMAL TECHNOLOGY, INC.

THYSSENKRUPP PRESTA AG

TIJET MEDIZINTECHNIK GMBH

TLS TECHNIK GMBH & CO

TOHNO SEIMITSU CO., LTD.

TOPMIM INTERNATIONAL

ULTRAFINE POWDER TECHNOLOGY, INC.

UNITED STATES BRONZE POWDERS, INC

UTRON, INC

WESTLAND CORP

WITTMANN-BATTENFELD

WITTMAN-BATTENFELD OF AMERICA, INC

WORLD CLASS TECHNOLOGY

ZOLLERN-MIMTEC

ZSCHIMMER & SCHWARZ GMBH & CO

CHAPTER EIGHT: PIM MATERIALS

INTRODUCTION

PRODUCTION OF POWDERS

SOLID-STATE REDUCTION

ATOMIZATION

ELECTROLYSIS

CHEMICAL

TABLE 18 NORTH AMERICAN POWDER SHIPMENTS BY TYPE OF MATERIAL AND PRODUCTION FOR MIM, THROUGH 2014 (SHORT TONS)

PIM MATERIALS

TABLE 19 PIM MATERIALS

TABLE 19 (CONTINUED)

TABLE 19 (CONTINUED)

TABLE 20 ALLOYS USED IN MIM STEELS

TABLE 20 (CONTINUED)

STAINLESS STEELS

Martensitic Stainless Steels

Ferritic Stainless Steels

Austenitic Stainless Steels

TABLE 21 NOMINAL COMPOSITIONS OF SOME STAINLESS STEELS, WT %

TABLE 22 THE TYPE OF STAINLESS STEELS AND THEIR MIM USES IN MEDICAL INSTRUMENTS

LOW ALLOY STEELS

NICKEL AND NICKEL ALLOYS

CONTROLLED EXPANSION ALLOYS

COBALT AND COBALT ALLOYS

COPPER AND COPPER ALLOYS

RHENIUM

TITANIUM

TABLE 23 TITANIUM AND TI-6AL-4V ALLOY COMPOSITIONS, WT %

TUNGSTEN

ALUMINUM

MARKET SHARES OF CERAMICS, METALS AND ALLOYS

TABLE 24 SHARE OF MIM MARKET BY METALS AND ALLOYS, 2009 AND 2014 (%)

FIGURE 4 SHARE OF MIM MARKET BY METALS AND ALLOYS, 2009 (%)

MIM ECONOMIC ISSUES

TABLE 25 HISTORICAL AND FORECAST PRICES OF MIM METALS, THROUGH 2014 ($/LB, AVERAGE FOR A YEAR)

FIGURE 5 HISTORICAL AND FORECAST PRICES OF MIM METALS, 2005-2014 ($/LB, AVERAGE FOR A YEAR)

STAINLESS STEEL

CARBON STEEL

TUNGSTEN

COPPER

NICKEL

Nickel (Continued)

CHAPTER NINE: CERAMIC MATERIALS

TABLE 26 SHARE OF CIM MARKET BY MATERIALS, 2009 AND 2014 (% SALES VALUE)

FIGURE 6 SHARE OF CIM MARKET BY MATERIALS, 2009 AND 2014 (% SALES VALUE)

ENGINEERING PROFILES

ALUMINA (AL2O3, 99.8% PURE ALUMINA)

TABLE 27 ENGINEERING PROFILE OF ALUMINA (99.8%)

ALUMINA (AL2O3, 96% PURE ALUMINA)

TABLE 28 ENGINEERING PROFILE OF ALUMINA (96%)

ZIRCONIA-TOUGHENED ALUMINA (AL2O3 + STABILIZED ZRO2)

TABLE 29 ENGINEERING PROFILE OF ZIRCONIA-TOUGHENED ALUMINA

ZIRCONIA (ZRO2, Y2O3-STABILIZED)

TABLE 30 ENGINEERING PROFILE OF ZIRCONIA-TOUGHENED ALUMINA

TABLE 30 (CONTINUED)

CERAMIC ECONOMIC PROFILES

ALUIMINA

ZIRCONIA

TABLE 31 HISTORICAL AND FORECAST PRICES OF CERAMIC MATERIALS (DOLLARS PER METRIC TON)

CHAPTER TEN: MARKETS AND APPLICATIONS

OVERVIEW

MARKET POTENTIAL

WIDE RANGE OF MARKETS

COST EFFECTIVENESS

NEW PRODUCT DEVELOPMENT

COST-EFFECTIVE TECHNOLOGY FOR POWDER PRODUCTION

TABLE 32 FACTORS CONTRIBUTING TO GROWTH OF PIM COMPONENTS

MARKETS FOR PIM COMPONENTS

MARKET SIZE

METAL INJECTION MOLDING

TABLE 33 GLOBAL SALES OF MIM COMPONENTS BY MARKET SECTORS, THROUGH 2014 ($ MILLIONS)

FIGURE 7 GLOBAL SALES OF MIM COMPONENTS BY MARKET SECTORS, 2009 (%)

AUTOMOTIVE

Automotive (Continued)

CONSUMER PRODUCTS

Consumer Products (Continued)

MECHANICAL

MEDICAL

REGIONAL FACTORS

TABLE 34 MIM SALES BY REGIONAL MARKET, 2009 ($ MILLIONS)

CERAMIC INJECTION MOLDING

TABLE 35 GLOBAL SALES OF CIM COMPONENTS BY MARKET SECTOR, THROUGH 2014 ($ MILLIONS)

FIGURE 8 GLOBAL SALES OF CIM COMPONENTS BY MARKET SECTORS, 2009 (%)

INVESTMENT CASTING CORES

CONSUMER PRODUCTS

MEDICAL

Medical (Continued)

IT/OFFICE AUTOMATION

INDUSTRIAL/MECAHNICAL

REGIONAL FACTORS

TABLE 36 CIM SALES BY REGIONAL MARKET, 2009 AND 2014 ($ MILLIONS)

FIGURE 9 GLOBAL SALES OF CIM COMPONENTS BY REGION, 2009

CHAPTER ELEVEN: POWDER INJECTION MOLDING PATENT ANALYSIS

FIGURE 10 TREND IN U.S. PATENTS FOR POWDER INJECTION MOLDING, 2002-2007 (NUMBER OF PATENTS AWARDED ANNUALLY)

FIGURE 10 (CONTINUED)

FIGURE 11 U.S. PATENTS AWARDED BY REGION IN 2007 AND FIRST 6 MONTHS OF 2008 (%)

CHAPTER TWELVE: POWDER INJECTION MOLDING PATENT ABSTRACTS

U.S. PATENT NO. 7,387,763

U.S. PATENT NO. 7,368,515

U.S. PATENT NO. RE40,273

U.S. PATENT NO. 7,361,995

U.S. PATENT NO. 7,351,765

U.S. PATENT NO. 7,351,371

U.S. PATENT NO. 7,347,968

U.S. PATENT NO. 7,335,696

U.S. PATENT NO. 7,303,722

U.S. PATENT NO. 7,288,222

U.S. PATENT NO. 7,285,088

U.S. PATENT NO. 7,279,126

U.S. PATENT NO. 7,275,896

U.S. PATENT NO. 7,275,329

U.S. PATENT NO. 7,259,219

U.S. PATENT NO. 7,259,212

U.S. PATENT NO. 7,237,730

U.S. PATENT NO. 7,235,211

U.S. PATENT NO. 7,232,473

U.S. PATENT NO. 7,199,211

U.S. PATENT NO. 7,199,174

U.S. PATENT NO. 7,192,546

U.S. PATENT NO. 7,189,277

U.S. PATENT NO. 7,183,360

U.S. PATENT NO. 7,172,725

U.S. PATENT NO. 7,172,333

U.S. PATENT NO. 7,163,569

U.S. PATENT NO. RE39,445

U.S. PATENT NO. 7,144,957

U.S. PATENT NO. 7,134,345

U.S. PATENT NO. 7,132,479

U.S. PATENT NO. 7,131,597

U.S. PATENT NO. 7,126,276

U.S. PATENT NO. 7,117,596

U.S. PATENT NO 7,103,981

U.S. PATENT NO. 7,097,393

U.S. PATENT NO. 7,094,821

U.S. PATENT NO. 7,063,815

U.S. PATENT NO. 7,052,710

U.S. PATENT NO. 7,036,550

U.S. PATENT NO. 7,036,227

U.S. PATENT NO. 7,018,583

U.S. PATENT NO. 6,997,401

CHAPTER THIRTEEN: LIQUID METAL INJECTION MOLDING

THIXO-MOLDING

INTRODUCTION

TABLE 37 LIQUID INJECTION MOLDING METAL MATERIALS

TABLE 38 HOW MAGNESIUM PROERITES STACK UP AGINST KEY COMPETITORS

TECHNOLOGY

TECHNOLOGY (CONTINUED)

COMMERICAL ISSUES

TABLE 39 INSTALLED BASE, THIXO-MOLDING MACHINES BY REGION, THROUGH 2014 (UNITS)

FIGURE 12 INSTALLED BASE, THIXO-MOLDING MACHINES BY REGION, 2009 AND 2014 (%)

TABLE 40 INSTALLED BASE, THIXO-MOLDING MACHINES BY REGION, THROUGH 2014 (METRIC TONS OF CAPACITY)

TABLE 41 MATERIAL CONTENT PER CAR (VEHICLES, EXCLUDING TRUCKS) (POUNDS)

THIXO CHALLENGES

TABLE 42 HISTORICAL AND PROJECTED COSTS FOR MAGNESIUM VERSUS KEY COMPETITORS (DOLLARS PER POUND)

NEW TECHNOLOGY

XYLOY MOLDING

TABLE 43 MELTING POINTS OF METALS

CHAPTER FOURTEEN: LIQUID INJECTION MOLDING COMPANY PROFILES

AB COMPONENTS

ADVANCED FORMING TECHNOLOGY—A DIVISION OF PRECISION CASTPARTS CORP

ADVANCED PROCESSING & MATERIALS

COOL POLYMERS

DATUMAG INC.

EF TECHNOLOGY (KUNSHAN) LTD

FCMP

G-MAG INTERNATIONAL

G-MAG EUROPE GMBH

HONG YA INDUSTRIAL

HUSKY INJECTION MOLDING SYSTEMS

JSW PLASTICS MACHINERY, INC

JURONG HUA-YE NEW TECHNOLOGY INDUSTRY CO. LTD

MG PRECISION

NEUE MATERIALIEN FUERTH GMBH

NISSEI PLASTIC INDUSTRIAL CO. LTD

NYPRO, INC.

PARKWAY PRODUCTS

PHILLIPS PLASTICS

PLUSTECH INC.

RAYCON INDUSTRIES, INC.,

SHANGHAI ZIYAN ALLOY TECHNOLOGY CO. LTD.

SIRRIS

TENMA CORPORATION

THIXOMAT

TOYO KAKO CO., LTD.

TOYOTA BOSHOKU CORP

VUJANOVIC HOLDING B.V

WAFFER

YAMAHA FINE TECHNOLOGIES

YORK IMPERIAL PLASTICS

CHAPTER FIFTEEN: LIQUID INJECTION MOLDING PATENT ABSTRACTS

U.S. PATENT NO. 7,341,094

U.S. PATENT NO. 7,343,959

U.S. PATENT NO. 7,353,858

U.S. PATENT NO. 7,331,375

U.S. PATENT NO. 7,237,594

U.S. PATENT NO. 7,232,305

U.S. PATENT NO. 7,163,046

U.S. PATENT NO. RE39,291

CHAPTER SIXTEEN: MAJOR CHALLENGES

MAJOR CHALLENGES

MAJOR CHALLENGES (CONTINUED)

MAJOR CHALLENGES (CONTINUED)

APPENDIX: GLOSSARY OF TERMS

GLOSSARY OF TERMS

GLOSSARY OF TERMS (CONTINUED)

GLOSSARY OF TERMS (CONTINUED)

GLOSSARY OF TERMS (CONTINUED)

GLOSSARY OF TERMS (CONTINUED)

GLOSSARY OF TERMS (CONTINUED)

GLOSSARY OF TERMS (CONTINUED)

GLOSSARY OF TERMS (CONTINUED)

GLOSSARY OF TERMS (CONTINUED)

GLOSSARY OF TERMS (CONTINUED)

GLOSSARY OF TERMS (CONTINUED)

GLOSSARY OF TERMS (CONTINUED)

GLOSSARY OF TERMS (CONTINUED)

GLOSSARY OF TERMS (CONTINUED)

LIST OF TABLES

SUMMARY TABLE 1 GLOBAL SALES OF MIM COMPONENTS

(POWDER) BY REGION, THROUGH 2014 ($ MILLIONS)

SUMMARY TABLE 2 GLOBAL SALES OF CIM COMPONENTS BY

REGION, THROUGH 2014 ($ MILLIONS)

SUMMARY TABLE 3 LIQUID METAL MOLDING REVENUES BY

REGION, THROUGH 2014

TABLE 1 ADVANTAGES OF POWDER INJECTION MOLDING

TABLE 2 DISADVANTAGES OF POWDER INJECTION MOLDING

TABLE 3 COMPARISON OF METAL INJECTION MOLDING WITH

SELECTED METAL FORMING TECHNOLOGIES

TABLE 4 METAL INJECTION MOLDED PRODUCTS BY MARKET

SECTORS

TABLE 5 A COMPARISON OF WATER AND GAS ATOMIZATION

PROCESSES

TABLE 6 FEEDSTOCKS FOR PIM

TABLE 7 MAJOR FIRMS SUPPLYING POWDERS AND

FEEDSTCOKS TO THE MIM INDUSTRY

TABLE 8 MAJOR NORTH AMERICAN FIRMS

MANUFACTURING PIM PARTS AND COMPONENTS

TABLE 9 MAJOR NON-U.S. FIRMS MANUFACTURING MIM

PARTS AND COMPONENTS

TABLE 10 MAJOR COMPANIES SUPPLYING EQUIPMENT TO THE PIM

COMPONENT MANUFACTURERS

TABLE 11 PIM CAPACITY AND MARKET SIZE BY GEOGRAPHICAL

REGION, 2009 ($ MILLIONS)

TABLE 12 GLOBAL SALES OF PIM COMPONENTS BY REGION,

THROUGH 2014 ($ MILLIONS)

TABLE 13 SALES AND MARKET SHARE OF MAJOR MIM COMPANIES

IN THE NORTH AMERICAN MIM MARKET, 2009 ($ MILLIONS, %)

TABLE 14 SALES AND MARKET SHARES OF MAJOR MIM COMPANIES

IN THE JAPANESE MIM MARKET, 2009 ($ MILLIONS, %)

TABLE 15 SALES AND MARKET SHARES OF MAJOR ASIAN MIM

COMPANIES, EXCLUDING JAPAN, 2009 ($ MILLIONS, %)

TABLE 16 SALES AND MARKET SHARES OF MAJOR EUROPEAN MIM,

2009 ($ MILLIONS, %)

TABLE 17 GLOBAL SALES AND MARKET SHARES OF MAJOR MIM

COMPANIES, 2009 ($ MILLIONS, %)

TABLE 18 NORTH AMERICAN POWDER SHIPMENTS BY

TYPE OF MATERIAL AND PRODUCTION FOR MIM,

THROUGH 2014 (SHORT TONS)

TABLE 19 PIM MATERIALS

TABLE 20 ALLOYS USED IN MIM STEELS

TABLE 21 NOMINAL COMPOSITIONS OF SOME STAINLESS STEELS,

WT %

TABLE 22 THE TYPE OF STAINLESS STEELS AND THEIR MIM USES

IN MEDICAL INSTRUMENTS

TABLE 23 TITANIUM AND TI-6AL-4V ALLOY COMPOSITIONS, WT %

TABLE 24 SHARE OF MIM MARKET BY METALS AND ALLOYS, 2009

AND 2014 (%)

TABLE 25 HISTORICAL AND FORECAST PRICES OF MIM METALS,

THROUGH 2014 ($/LB, AVERAGE FOR A YEAR)

TABLE 26 SHARE OF CIM MARKET BY MATERIALS, 2009 AND 2014 (%

SALES VALUE)

TABLE 27 ENGINEERING PROFILE OF ALUMINA (99.8%)

TABLE 28 ENGINEERING PROFILE OF ALUMINA (96%)

TABLE 29 ENGINEERING PROFILE OF ZIRCONIA-TOUGHENED

ALUMINA

TABLE 30 ENGINEERING PROFILE OF ZIRCONIA-TOUGHENED

ALUMINA

TABLE 31 HISTORICAL AND FORECAST PRICES OF CERAMIC

MATERIALS (DOLLARS PER METRIC TON)

TABLE 32 FACTORS CONTRIBUTING TO GROWTH OF PIM

COMPONENTS

TABLE 33 GLOBAL SALES OF MIM COMPONENTS BY MARKET

SECTORS, THROUGH 2014 ($ MILLIONS)

TABLE 34 MIM SALES BY REGIONAL MARKET, 2009 ($ MILLIONS)

TABLE 35 GLOBAL SALES OF CIM COMPONENTS BY MARKET

SECTOR, THROUGH 2014 ($ MILLIONS)

TABLE 36 CIM SALES BY REGIONAL MARKET, 2009 AND 2014 ($

MILLIONS)

TABLE 37 LIQUID INJECTION MOLDING METAL MATERIALS

TABLE 38 HOW MAGNESIUM PROERITES STACK UP AGINST KEY

COMPETITORS

TABLE 39 INSTALLED BASE, THIXO-MOLDING MACHINES BY

REGION, THROUGH 2014 (UNITS)

TABLE 40 INSTALLED BASE, THIXO-MOLDING MACHINES BY

REGION, THROUGH 2014 (METRIC TONS OF CAPACITY)

TABLE 41 MATERIAL CONTENT PER CAR (VEHICLES, EXCLUDING

TRUCKS) (POUNDS)

TABLE 42 HISTORICAL AND PROJECTED COSTS FOR

MAGNESIUM VERSUS KEY COMPETITORS (DOLLARS

PER POUND)

TABLE 43 MELTING POINTS OF METALS

LIST OF FIGURES

SUMMARY FIGURE REGIONAL PERCENTAGE SHARE OF SALES OF

MIM COMPONENTS, 2009 AND 2014 (%)

FIGURE 1 GLOBAL SALES OF PIM COMPONENTS BY REGION, 2009

AND 2014 ($ MILLIONS)

FIGURE 2 MARKET SHARE OF MAJOR COMPANIES IN THE NORTH

AMERICAN MIM MARKET, 2009 (%)

FIGURE 3 MARKET SHARE OF MAJOR COMPANIES IN THE

JAPANESE MIM MARKET, 2009 (%)

FIGURE 4 SHARE OF MIM MARKET BY METALS AND ALLOYS, 2009

(%)

FIGURE 5 HISTORICAL AND FORECAST PRICES OF MIM METALS,

2005-2014 ($/LB, AVERAGE FOR A YEAR)

FIGURE 6 SHARE OF CIM MARKET BY MATERIALS, 2009 AND 2014 (%

SALES VALUE)

FIGURE 7 GLOBAL SALES OF MIM COMPONENTS BY MARKET

SECTORS, 2009 (%)

FIGURE 8 GLOBAL SALES OF CIM COMPONENTS BY MARKET

SECTORS, 2009 (%)

FIGURE 9 GLOBAL SALES OF CIM COMPONENTS BY REGION, 2009

FIGURE 10 TREND IN U.S. PATENTS FOR POWDER INJECTION

MOLDING, 2002-2007 (NUMBER OF PATENTS AWARDED

ANNUALLY)

FIGURE 11 U.S. PATENTS AWARDED BY REGION IN 2007 AND FIRST

6 MONTHS OF 2008 (%)

FIGURE 12 INSTALLED BASE, THIXO-MOLDING MACHINES BY

REGION, 2009 AND 2014 (%)