Joshua Galyon
PBTT Corp is an Indiana-based manufacturing company focused on sustainable practices, clean technology, and advanced production methods across industries such as aerospace, automotive, and energy. Established in 2013, the company integrates engineering expertise with a range of manufacturing services, including machining, finishing, heat treatment, and metal injection molding. With a commitment to green manufacturing and operational efficiency, PBTT Corp supports clients by delivering consolidated, high-quality solutions. Its teams emphasize innovation, safety, and professional integrity, while leveraging advanced processes such as NANOFORM to optimize materials and production outcomes. Through vertically integrated capabilities and continuous investment in employee development, PBTT Corp remains aligned with evolving industry demands for precision components and scalable manufacturing solutions.
How Metal Injection Molding Works
PBTT Corp. offers next-generation services that include high-speed metal injection molding (MIM). Traditionally associated with plastics, injection molding is a process of injecting plastic, heated to a point of liquefaction, at high pressure into a temperature-controlled mold. Once the liquefied plastic fills the mold, the cooling process begins, creating finished three-dimensional parts that are easily removable when opening the mold by machine.
The production sequence, from mold closing and injection shot, to removal of a finished part, requires injection molding machines (IMMs). These are rated according to tons of mold clamping force, with micro IMMs representing just a few tons of force and used to create very small parts. On the other end of the spectrum, extremely large IMMs provide more than 3,000 tons of clamping force and support very large molds (and correspondingly large parts). In the plastic injection molding sphere, common examples include vehicle bumper covers and front fascia.
Metal injection molding applies the flexibility of plastic injection molding to a much stronger material. This enables the production of complex, high precision metal parts, required in industries spanning medical devices, automotive, aerospace, electronics, and firearms. Common automotive applications of MIM include sensor components and fuel system parts, particularly in turbocharger manifolds. These contain high-precision variable turbine geometry systems.
Within the medical sphere, surgical equipment in areas such as orthopedics often requires precisely machined elements at a micro-scale. In electronics, MIM is often required for connectors and heat sinks, while advanced firearms contain extremely small, calibrated moving parts.
One key advantage of metal injection molding is reduction of the cost of production at high volume. It offers a combination of minimal waste and engineered strength. Though the original mold is expensive and time-consuming to produce, it can be used many thousands of times over.
In producing the metal that is liquefied, MIM manufacturers traditionally combine metal powders–including stainless steel, tool steels, and titanium–with a binder. This feedstock is injected into the mold, with heat applied to eliminate the binder and create a denser material. This process is known as sintering and creates the strength needed for durable, precision components, with thin yet strong walls. The components combine high strength with resistance to wear and require minimal post-processing after being removed from the mold.
There are a few drawbacks to MIM, including the inherent design complexity of molds, which tends to make them unsuitable for low-volume production. In addition, the sintering process, including binder removal, must be carefully monitored, to avoid defects and changes in dimension. Uneven sintering is associated with unwanted cracking, warping, and shrinkage, which impact part functionality and quality. The cycle time of MIM is relatively long, as the sintering process takes time to complete. Compared with plastic injection molding, MIM requires longer lead times when large production volumes are involved.
The PBTT metal injection molding process involves thixomolding, a process for semi-solid magnesium alloys. Thixomolding allows for significantly lower temperatures of injection compared with fully liquid, hot chamber, aluminum, and magnesium die casting. In addition, having a semi-solid material minimizes porosity and delivers higher process yield. This in turn extends die life and improves component dimensional consistency, resulting in minimal tooling maintenance expenses.
About PBTT Corp
PBTT Corp is a Newburgh, Indiana-based manufacturing company established in 2013, with a focus on sustainable operations, clean technology, and advanced production processes. Serving industries such as aerospace, automotive, and energy, PBTT Corp offers integrated services including machining, metal injection molding, and finishing. Its engineering teams bring expertise in advanced processes like NANOFORM, while the company emphasizes employee development, safety, and professional integrity alongside its commitment to green manufacturing practices.
