Indo-MIM

Indo-US MIM Tec. Pvt. Ltd.; popularly known as Indo-MIM headquartered in Bangalore, India is a leading global supplier of precision-engineered products using Metal Injection Molding (MIM) as the core manufacturing technology. Dr. Krishna Chivukula (67) is a first generation entrepreneur who started Indo-US MIM Tec. Pvt. Ltd. (Indo-MIM) in 1998 with offices in India and USA and at the same time also owns Shiva Analyticals India Pvt. Ltd., Indo-MIM Precision Investing Casting in Tirupati, India and Advanced Analytical Testing Laboratory Inc, USA.

Indo-MIM presently has sales offices at USA, Germany and China with Sales Representatives at every nook and corner of the globe. Over the past 17 years, with the MIM technology, Indo-MIM has successfully helped its customers migrate from complex-shaped steel components in conventional machining and casting technologies to MIM.

Today, Indo-MIM has achieved a leadership position in the field of MIM, providing precision-engineered products to customers in more than forty countries in the Americas, Europe and Asia. Indo-MIM is a fully integrated MIM parts producer with capabilities and proficiency in design, tooling, materials and a full range of finishing and assembly operations. The state-of-the-art manufacturing capability of Indo-MIM is a fusion of two units spread over 390,000 square feet - the world’s largest installed capacity for Metal Injection Molding. The modern facilities have a combined strength of over 2700 skilled engineers, scientists, technicians and manufacturing associates.

History

In 1997, AF Technologies India Pvt. Ltd. was founded as a 50-50 joint venture with a renowned North American MIM company and an Indo-American industrialist with the intent of establishing a manufacturing base for MIM products in India. A core team of Indian engineers, metallurgists, designers, toolmakers and technicians were trained in MIM technology with the US partner. In 2001, 100% ownership of the venture was achieved from the American collaborator and Indo-US MIM Tec (P) Ltd. was born. Today, after 17 years of supplying MIM products to companies across the globe, the customers have come to know the company as simply, Indo-MIM.

Corporate Affairs- Chairman Profile

Dr. Krishna Chivukula (67) is a first generation entrepreneur who started Indo-US MIM Tec. Pvt. Ltd. (Indo-MIM) with offices in India and US a decade and half ago. He is also the Chairman and Owner of Shiva Analyticals India Ltd, Indo-MIM Precision Investing Casting in Tirupati, India and Advanced Analytical Testing Laboratory Inc, USA. Earlier positions held by him were:

• Director, Mergers and Acquisitions; Bird Johnson Company - Massachusetts, USA, 1981–84
• President and Chief Executive Officer, Hoffman Group of Companies, New York - seven company multinational manufacturing group, 1984–90
• Owner and Chairman, Shiva Technologies Inc, New York and Toulouse, France, 1990-2006

Dr. Krishna Chivukula holds a B.Tech Honors degree from IIT Bombay (1968), M. Tech with distinction from IIT Madras (1970) and MBA from Harvard Business School 1980. He has been conferred with an honorary doctorate D. Litt. from Tumkur University, Karnataka, India for his and company’s immense contribution to humanitarian philanthropic activities. Born in India, he is an American citizen, settled in New Jersey USA. He divides his time between India and US working on technology oriented projects. His wife Dr. Jagadamba is an eminent neonatalogist trained in Bangalore and USA. She is currently retired and living in USA. His son, Krishna Chivukula Jr. is the CEO and Managing Director of the company, who aims to take the company to a next level.

Metal Injection Molding Process

The MIM process combines the design flexibility of plastic injection molding with the strength and integrity of wrought metals to offer cost effective solutions for highly complex part geometries. The MIM process is explained in four unique processing steps (Compounding, Molding, De-binding and Sintering) to produce a final part. In the process of Compounding, fine metal powder less than 20µ particle size is blended with thermoplastic and wax binders in precise amounts which is then heated to a temperature causing the binders to melt. The mass is cooled and then granulated into free flowing pellets (termed feedstock) that will be accepted by the injection molding machine. In Molding, the pelletized feedstock is fed into a molding machine, where it is heated and injected into a mold cavity under high pressure. The part (now termed green part) is allowed to cool and then ejected from the mold so the process can repeat. After Molding, it goes through De-binding, which is a process where the binder materials are removed from the molded component. This process is usually done in several steps whereby the majority is removed before it goes for the sintering, leaving behind enough binder to handle the parts into the sintering furnace. Finally goes through Sintering, where the de-bound parts are placed on ceramic setters which are loaded into a high temperature, atmosphere controlled furnace. The parts are slowly heated in a protective atmosphere to drive out the remaining binders. Wherein the binders are evaporated, the part is heated to high temperature where the void space between the particles is eliminated as the particles fuse together. The part shrinks tropically to its design dimensions and transforms into a dense solid. The sintered density is typically greater than 97% of theoretical for most materials.

The end-product MIM metal has comparable mechanical and physical properties with parts made using classic metalworking methods and MIM materials are compatible with the same subsequent metal conditioning treatments such as plating, passivating, annealing, carburizing, nitriding, and precipitation hardening.

MIM Application

The window of economic advantage in metal injection molded parts lies in complexity and volume for small-size parts. MIM materials are comparable to metal formed by competing methods, and final products are used in a broad range of industrial, commercial, medical, dental, aerospace, and automotive applications.

Indo-MIM Market Segments

Indo-MIM has been catering to Automotive, Medical, Industrial and Consumer markets quite efficiently:

Automotive Segment

Indo-MIM is a leading and trusted global supplier of many critical MIM components for the automotive industry in a wide variety of vehicle safety, fuel system, powertrain and interior applications.

MIM automotive product solutions:

• Safety Systems: Sensor housings, braking & ABS components, seat belt mechanisms
• Fuel Systems: Injector nozzles, armatures, housings Interior Systems Seating mechanisms,
• Powertrain: Turbocharger vanes and components, hydraulic spools, rocker arms
• Electrical Systems: Connectors, heat sinks

Indo-MIM Automotive capabilities:

• Automated manufacturing & inspection
• Precision grinding and CNC machining
• Heat-treating plating and surface coatings
• Plastic insert molding
• Assembly and integration
• Product design and material selection assistance
• Prototyping and low volume development
• High volume MIM production

Medical Segment

Indo-MIM provides industry-leading solutions for MIM medical device, orthopedic and orthodontic applications. Indo-MIM is a single resource for medical products right from concept design and prototype throughout fabrication, integration and packaging. It provides cost effective one-stop solutions for the most demanding medical product needs.

MIM Medical product solutions:

• Surgical Instruments: Endoscopic graspers & scissors, instrument bodies, scalpel handles, forceps, endoscopy, ablation electrodes.
• Orthopedic: Trauma plates, screws, spine (implants & external fixation) orthopedic surgery tools (power & hand)
• Orthodontic & Dental: Orthodontic brackets, dental instruments Hearing Devices Housings and implants

Indo-MIM Medical capabilities:

• Product design and material selection assistance
• Prototyping and low volume development
• Low and high volume MIM production
• Micro-molding
• Automated manufacturing and inspection
• Precision grinding and CNC machining
• Laser [...] and welding
• Heat-treating and PVD surface coatings
• Micro-blasting and passivation
• Plastic insert molding
• Plastic injection molding
• Integration and packaging in ISO Class 8 cleanroom

Consumer Segment

Consumer products demand creatively engineered designs married with high strength materials wrapped in attractive finishes. Indo-MIM satisfies this need with the unbeatable design and material flexibility of MIM strengthened with the world-class production and finishing capabilities. Indo-MIM is a leading global supplier of custom engineered MIM products for defence, sporting goods, electronic, tools and hardware applications.

MIM consumer product solutions:

• Defence: Hammers, triggers, sears, extractors, sights, safeties, magazine catches, levers, selectors, grip safeties, trigger guards
• Archery: Broadheads, sights, cross bow mechanisms, release aids
• Multi Tools & Knives: Drivers, bit holders, clips, blades, cosmetic inserts
• Golf: Sole plates, weights of engineered density
• Cycling: Derailleur parts, braking parts, clipless pedals
• Mobile Telephone: Hinge mechanisms, buttons, cosmetic inserts
• Computer Peripherals: Voice coil motor, head parking mechanisms, printer cores
• Hand & Power Tools: Handles, bits, keyless chucks, blade clamps

Indo-MIM consumer product capabilities:

• Product design and material selection assistance
• Industrial design services
• Prototyping and low volume development
• High volume MIM production
• Automated manufacturing and inspection
• Precision grinding and CNC machining
• Heat-treating, plating, blackening and PVD coatings
• Bead and grit blasting, machine and hand polishing
• Plastic insert molding
• Assembly and integration

Industrial Segment

From high strength structural parts to tiny fiber optic connectors, industrial components demand high performance and high reliability at a competitive cost and Indo-MIM is here to meet that challenge.

MIM Industrial product solutions:

• Door hardware: Lock housings, cylinders, carriers, pins
• Hand and power tools: Handles, bits, keyless chucks, blade clamps, pawls, ratchet mechanisms
• Electronics: Sensor housings, fiber optic connectors, microwave packages, heatsinks
• Hydraulics: Value spools, housings, lavatory fixtures
• Fasteners and Hardware
• Plumbing: Valve spools, faucet hardware
• Safety: Fall protection mechanisms
• Oil & Gas: Valve components for high corrosion applications

Indo-MIM Industrial product capabilities:

• Product design and material selection assistance
• Industrial design services
• Prototyping and low volume development
• High volume MIM production
• Micromolding
• Automated manufacturing & inspection
• Precision grinding and CNC machining
• Heat-treating, plating and coatings
• Plastic insert molding
• Assembly and integration

MIM advantages over conventional method

The Metal Injection Molding process provides the ability to design unique products without the cost restrictions that would be found with conventional metal forming techniques. The MIM process combines the design flexibility of plastic injection molding with the strength and integrity of wrought metals to offer cost effective solutions for highly complex part geometries. Many industries now rely on MIM’s unique advantages to help them keep ahead in a highly competitive world.

• Ability to produce small, highly complex shapes in high volumes
• A wide variety of alloys with properties similar to wrought metal
• Net shape features with fine detail and good tolerance control
• Nearly unlimited shape capability in hard to process materials
• Achieve complexity that is cost prohibitive by any other route

Indo-MIM: In-house Tool Room and In-house Secondary Operations

In-house Tool Room

MIM is a metal forming process, and hence the Mold (or Tool) has a prime importance in ensuring that the right contour and size is accomplished. This is one of the main reason that Indo-MIM has established in-house Tool Making capabilities which is one of its kind in the industry.

All the global customers benefit from this in-house resource, in form of lower lead times as well as adaptability of change in design / correction, when required. This is a great competitive advantage for the customers when they have to launch their products into the market and win business ahead of their competition. Needless to say, an in-house Tool Room allows Indo-MIM to give lower prices for Tools and faster speed. Indo-MIM works with partnership module with its global customers, thereby gaining their confidence and patronage.

With the available set of equipment in the Tool Room, Indo-MIM has a capacity of manufacturing 45 ~ 50 Tools every month. The team continuously works on capability improvements and has built a structured knowledge base that helps for future programs.

In-house Secondary Operations

Indo-MIM has an integral manufacturing set-up that includes MIM process as well as the in-house secondary (post-MIM) processes for MIM parts. It is since 2009 that Indo-MIM started focusing on productivity improvement projects in ISP (in-house secondary process) and thereby reducing the man-hours in secondary processes. GeneRally secondary processes carried out are press coining, manually operated toggle coining, drilling, reaming, 100% dimension checking, and 100% visual inspection sometimes using microscopes based on critical requirements of the customer.

Other Manufacturing process at Indo-MIM

Other than Metal Injection Molding, the company has also got other manufacturing processes- Investment Casting, Ceramic Injection Molding and Precision Machining & Special Processes

Investment Casting

Indo-MIM manufactures & supplies high quality precision investment castings in a wide range of materials such as Steel, Nickel and Cobalt base for industrial and aerospace applications. Established in 2009, Indo-MIM’s Investment Casting plant has a state-of-the-art 30,000 square feet manufacturing facility in Tirupati, Andhra Pradesh, India.

With the plant being certified with ISO 9001:2008, ISO/TS 16949:2009, AS 9100 Rev. C, ISO 14001:2004 and OSHAS 18001:2007 system requirements; has capability to produce annual volumes from less than 1K to100K of highly complex shaped parts. The other capabilities include:

• Part spectrum extending from 10gms to 15 kg
• Flexible part size options - lengths up to 400 mm and thickness from 1 mm to 75 mm
• Short product development cycle - comparable with the best in the industry
• Castings in a wide range of air-melt alloys - including carbon and low alloy steels, 300 & 400 series SS, precipitation hardening stainless steels, nickel and cobalt based alloys an integrated manufacturing environment
• In-house mold and casting process design
• Modern Mold Manufacturing CNC Machining centers, EDM and Spark Erosion machines
• Primary and secondary production facilities from world class suppliers
• Inspection, testing and measurement capabilities based on global equipment inputs
• Engineers, Metallurgists and skilled technicians with a combined experience of over 10+ years in the field

Precision Machining and Special Processes

Indo-MIM-Aerospace Products Group (APG), situated on a 16 acre campus north of Bangalore, India, provides an end to end solution for precision machined components. From the 28,000 square foot facility, APG perform machining, inspection, NDT, chemical processing, plating and painting to the strictest global standards. The “one stop shop” reduces supply chain complexity and lead times by incorporating the widest variety of special process in one campus in India.

The major ingredient in the rapid growth has been a focus on quality without any compromise. Lean manufacturing techniques to reduce cycle times, cost and waste in the production process is utilized. Paired with the expertise in special processes, Indo-MIM APG is an effective solution to reduce cost while keeping superb quality.

With the best practices followed like fully equipped quality clinic, Lean Six-Sigma and Microsoft AXAPTA ERP system implementation; the facility is certified with NADCAP in June 2014 for all the processes in the facility, AS 9100 Rev.C certified in June 2014 for all the processes available at the facility, numerous OEM approvals for engine components, actuation and landing gear and ISO 140001 Compliant

Core Capabilities of APG

Modern Facility:

• Finished Epoxy Floors
• Bright and air-conditioned environment for working
• Well segregated storage for incoming and accepted raw materials
• Equipped with back-up power generation in the facility
• UPS unit available on each machine
• FOD controlled de-burring and part finishing benches

Wide Machining Capabilities:

• Availability of 3 and 4 axis DMG ™ milling machines which are capable of manufacturing parts of 800 mm size
• Hass ™ Turning lathes with bar feeders capable of turning parts up to 350 mm diameter
• DMG ™ HMC center w/pallet changers
• DMG ™ turn-mill centers
• Okamoto ™ surface grinding machine
• Universal Grinding Machine
• Jig Boring
• Lapping

Fully Equipped Quality Inspection Room

• Temperature controlled atmosphere
• Brown & Sharp 1.5 Meter Bed CMM
• Contour testing machine
• VMS-60X magnification machine
• Height Gauge

Ceramic Injection Molding

Ceramic has been a material of preference for demanding parts that require high resistance to heat, corrosion, and wear. Today, Indo-MIM’s Ceramic Injection Molding (CIM) services make it possible to manufacture this durable material into small and micro-sized parts with complex geometries.

CIM is ideal for high volume production of complex, tight tolerance components, ceramic injection molding offers significant advantages over conventional forming methods:

• Cost effective technique for complex designs
• Ability to produce net or near-net shape parts
• Very tight tolerance control
• Low-cost, high volume manufacturing runs

Ceramic is made of inorganic, non-metallic material. Explained simply, any solid material that is not a plastic or metal can be defined as a ceramic. In applications where plastic or metals won’t effectively function, ceramic has been the solution.

Advantages of CIM:

First, during the design phases, Indo-MIM conducts mold flow simulation and analysis in order to optimize the part and mold design. By performing this analysis early in the design process, prior to commissioning the injection mold, many problems can be addressed and improvements can be implemented quickly at low cost and without causing expensive delays in the production schedule.

A second key factor in achieving tight tolerances and high repeatability is quality control during the mixing process to create a homogeneous pelletized feedstock. The ceramic particles must have a consistent size and they must be distributed evenly in the polymer binder. The use of sub-micron powders allows for smaller features that would otherwise not be possible with larger granulate-based forming methods such as dry pressing and such precautions are well taken care in advance to avoid any mishap. And the third critical refinement implemented is cavity pressure containment and control. Cavity pressure is the process variable that correlates most directly with part quality.

Ceramic materials are tough enough to withstand acid corrosion, extreme heat, heavy friction, high pressure, ongoing abrasion, and exposure.

Indo-MIM Customer Support

In 2004 Indo-MIM started marketing its products/services globally and with the plants 5,000 to 10,000 miles away from many customer locations, it was concerning that the time differences might inhibit communication with the existing customers; hence it was decided that the best way to address this issue was to have dedicated technical sales staff and dedicated customer support staff in the same geographic regions as the customers.

By 2007 Indo-MIM had fully staffed sales and marketing offices in the USA and Germany. Today the network of sales and distribution centers has included offices in Shanghai, Taipei and Tokyo.

The sales offices are staffed with factory-trained engineers and many of them have worked in product engineering, quality, or operations. Having factory trained engineers graduate into the MIM sales force ensures that Indo-MIM’s technical selling staff understand the MIM technology and can help customers use MIM to solve their design or manufacturing problems cost-effectively.

Quality System

Indo-MIM’s approach towards quality follows several basic principles: strategic planning and leadership, a strong focus on the customer, fact-based management, continuous improvement and total employee involvement.

The quality system, combined with a refined business system provides the fundamental structure for meeting and exceeding the customers’ needs and expectations. As the ongoing improvement effort focus on refining the processes and controls, Indo-MIM is able to provide the highest quality and service in the industry.

Best practice methodologies are employed throughout the company with the emphasis to provide the highest level of customer satisfaction. These methodologies include Lean Six Sigma, 5S Visual Management, Kaizen Principles, Strategic Supplier Integration and Total Productive Maintenance. Indo-MIM’s commitment to quality has helped the company to earn a “Self Certified” status from many of the Fortune 500 customers.

Quality Certifications

CSR Activities

Indo-MIM started its CSR activities more than a decade ago, under the aegis of Sri Sathya Subbarama Shastry Memorial Trust and Chivukula Trust. The primary objective was to develop, maintain and promote educational and medical assistance programs to schools, hospitals and child welfare centers- for the benefit of marginalized and underprivileged sections of the society

The Chivukula Trust has donated state-of- the art cardiology equipment at the cost of Rs. 4 crore to Bangalore Baptist Hospital and have been donating Rs. 30 lakhs annually towards financial assistance of poor patients.

Under the program “Lalitha Dasoha”; Indo-MIM has been providing balanced and nutritious mid-day meals to 2000 children in various Government schools in Bangalore.

Not only the mid-day meals and medical assistance; but the trust is also involved in providing assistance to HIV patients. Indo-MIM provides Rs. 3 lakhs per month to Asha Foundation- an organization that treats HIV patients from economically weaker sections of the society. Through the foundation, the trust has been financing the procurement of ART drugs for 50 mothers suffering from AIDS.

Environmental protection is another aspect kept under consideration. Indo-MIM has undertaken a noble initiative to commence association with “www.grow-trees.com”, which gives companies an easy way to go green by allowing them to plant trees. Indo-MIM has pledged to plant 12000 trees during the financial Year 2014-2015, to show deep commitment towards protection of environment

Awards & Recognitions

Indo-MIM has been recognized with various awards for its innovative designs and creativity towards the technology. Metal Powder Industries Federation (MPIF) is a “not-for-profit association” formed by the Powder Metallurgy industry to advance the interests of the metal powder producing and consuming industries. Indo-MIM has been recognized by MPIF with 8 awards for the innovative and efficient designs developed by the designers.

In recognition of developing various MIM and Investment Casted components, Indo-MIM has been presented this year (2014) with “Best Supplier Innovation Award”, a Memento of recognition by Cummins Inc. for their efforts in developing various critical components through integrated technology and product innovation.

Various awards have been won by the company from organizations under State Government for excelling in awarding the products and for keeping the safety measures in control.

Marketing and Promotional activities/ Exhibitions

Throughout the year, Indo-MIM participates in a wide variety of internationally recognized exhibitions, conferences and trade fairs in the USA, Europe and Asia like MEDTEC, MEDIX, MD&M, HANNOVER MESSE, FENSTERBAU FRONTALE etc. Not only Indo-MIM exhibits its product in an innovative way in these exhibitions; but they get recognized globally for all the efforts put in building the brand worldwide.

Not only the participation is under count; but the company has been efficiently organizing seminars at places like China, USA etc; which has expanded the horizons to the target audience.