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Two-material combinations to form a single component are possible by welding or brazing, but a more cost-effective and higher quality means is to assemble small pieces into the final integral shape during initial forming. If sintering is controlled, then the final object has an integral metallurgical bond, yet functionality within that component that is placed to the designer needs. Although tooling is more expensive for bi-metal molding, automotive applications justify the set-up expense of this new metal powder injection molding process. Candidate applications are associated with selective function as desired, such as in sensors, actuators, fuel injectors, and wear components. The scale-up of the process is demonstrated with several geometries and applications.

Powder injection molding (PIM) combines the processability of plastics and the superior material properties of metals and ceramics to form high performance components. The process comprises of several stages. Metal or ceramic powder and organic materials are combined into a homogeneous feedstock which is then injection molded into a desired shape. The organic constituent is then removed from the object and sintering is done to form a rigid structure of controllable density. The important benefits afforded by PIM include near net-shape production of complex geometries in the context of low cost and rapid fabrication at high production volumes.