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MIM Case Study – Banjo Fitting

This case study explores the application of Metal Injection Molding (MIM) technology in creating banjo fittings for all-terrain vehicles. The fittings must meet stringent requirements, including structural integrity at 13.8 MPa (2,000 PSI) and hermetic sealing. We detail the competing technology, machining, and provide specifications such as dimensions, weight, and material properties. The unique challenges of maintaining thin wall thicknesses and achieving corrosion resistance are addressed, alongside the advantages of using MIM in production consistency and tooling efficiency.

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MIM Case Study – Banjo Fitting

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  1. MIM Case Study – Banjo Fitting • Application: All-Terrain Vehicles Brake System • Functional Requirements: Structurally intact; Withstand 13.8 Mpa (2,000 PSI) Pressure (proof test) • Competing Technology: Machining • Overall Size: • Overall length 40 mm, bolt retain section 13.5 mm • I.D. 2 .0 mm, wall thickness as thin as 0.7 mm • Part Weight: 11.6 grams (barbed), 15.0 grams (straight) • Material: MIM-17-4 PH, H-1100 Heat Treat

  2. MIM Case Study – Banjo Fitting Key Requirements: 1. Hermetic at 2,000 psi 2. Free fluid passage in the 2 mm ID 3. Bolt sealing surfaces free of flash and parting line 4. Make both part types in same mold base 5. Reasonable corrosion resistance

  3. MIM Case Study – Banjo Fitting Contoured, flash & parting-line free sealing surfaces on both sides of 6 mm bolt hole 2 mm ID for hydraulic fluid passage Gate

  4. MIM Case Study – Banjo Fitting Bolt Head Width : 13.5 mm Shaft Length 33 mm

  5. MIM Case Study – Banjo Fitting Thin wall on barbed component needed to withstand 2,000 psi & maintain hermeticity. O.D - 3.4 mm I.D. - 2.0 mm

  6. MIM Case Study – Banjo Fitting Notch in 6 mm Bolt ID pins (both sides of tool) captures 2 mm ID pin Parting line in center of 6mm bolt hole creates smooth surfaces for crush washers Interchangeable tooling insert that allows both barbed & straight features to be molded

  7. MIM Case Study – Banjo Fitting • Why MIM? • 17-4 Material more than adequate for strength & corrosion requirements • 2 mm ID, difficult to machine, is straightforward for MIM (straightness not an issue) • Molded bolt hole surfaces create smooth mating surfaces for crush washers • Both part types easily made in the same tooling • MIM consistency created few problems in production

  8. MIM Case Study – Banjo Fitting • Conclusion • Application worked well for MIM. • An example of how some of the “easy” attributes of MIM can be very useful to end users

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