Normally metal powder injection molding relies on high strength tool steel when creating a mold to form components. The problem with steel tooling is the long lead time and high cost for early test components. This project relies on low strength plastic tooling generated by rapid prototype technologies using computer-aided design files and very lowviscosity powder-binder feedstocks to make first trial pieces using metal injection molding powders. The intent is to investigate the possibilities, limitations, and time from concept to metal components through the use of plastic three-dimensional printed tooling. About half the time is associated with the rapid prototype mold build and the remainder is molding (pouring), debinding, and sintering. Demonstrations with common metal injection molding powders are included. One of the significant barriers was in sustaining low pressures due to the weak plastic tooling, but then how to pack the cavity to attain a high solids loading (powder content). This required considerable feedstock and binder experimentation to isolate a suitable feedstock of proper viscosity and powder-wetting characteristics. This thesis focuses on demonstrations primarily in ferrous systems.
