3D metal parts can now be injection molded

A new metal material molds like plastic but is stronger than die cast metals


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Xyloy injection-moldable metal can be molded in 3D net-shape parts in high volumes. Shown are a Xyloy part (left) and PC (polycarbonate) part (right).

In a move that promises to capture the attention of OEMs in both the plastics and metals industries, a fast-growing, innovative materials developer can now injection-mold metal parts on standard injection-molding machinery, and in tools designed for plastic.

This breakthrough comes about as a result of a new metal alloy developed by Cool Polymers, Inc. Xyloy is stronger than die cast metal parts and has no porosity. The material is molded in 3D net-shape parts in high volumes. It offers strength, stiffness, conductivity, and processability, with tooling guaranteed for the life of the program.

Company officials note that the new process is NOT metal injection molding (MIM), but rather standard injection molding of Xyloy injection-moldable metal. Many designs currently being die cast or plastic designs that might benefit from metal properties can now be injection molded using proprietary Xyloy injection-moldable metal. Shrinkage is less than 0.5%, according to the company.

Cool Polymers will manufacture parts for OEMs that are seeking to find better and more productive ways to produce metal parts, or replace under-performing plastic parts with metal. Cool Polymers offers full art-to-part design and molding services.

Of particular note is that metal parts made from Xyloy metals can be manufactured (injection molded) with existing tooling for plastics. Further, unlike metal parts, no secondary operations after molding are necessary. Finished parts can be textured or can accept standard finishes. In addition, molded parts can be painted and powder coated.

Injection-molding cycle times of nonporous Xyloy metal parts are on a par with plastic parts, according to the company. Properties of the new thermoplastic metal are:

  • Ultimate tensile strength of 47 kpsi (325 Mpa)
  • Yield strength of 36 kpsi (250 Mpa)
  • Elongation at break of 2%
  • Modulus of elasticity 13,000 kpsi (90 Gpa)
  • Specific heat capacity 0.1 BTU/lb°F (0.4 J/g°C)
  • Thermol conductivity 110 w/mk

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Cool Polymers

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