Abstract: Although MIM (metal injection molding) has received widespread application, aluminum has not been widely used for MIM in the prior art because of the tough oxide layer that grows on aluminum particles, thus preventing metal—metal bonding between the particles. The present invention solves this problem by adding a small amount of material that forms a eutectic mixture with aluminum oxide, and therefore aids sintering, to reduce the oxide, thereby allowing intimate contact between aluminum surfaces. The process includes the ability to mold and then sinter the feedstock into the form of compacted items of intricate shapes, small sizes (if needed), and densities of about 95% of bulk.

Abstract: An interlocking assembly of a voice coil motor for a hard disk drive having an arcuate shaped hollow structure formed by metal injection molding. The hollow structure has a bottom plate member that is separated from a top plate member by a pair of upright members disposed therebetween. The upright members joined with the inside surfaces of the plate members. The uprights are disposed at each end of the hollow structure. A tapered recess is formed in the top surface of the bottom plate, the recess ingress's from a convex edge of the bottom plate and narrows while extending through to an opposite concave edge, the tapered recess has side edges shaped to tightly interlock with a flat arcuate shaped permanent magnet having dovetail side edges to slidely interlock with the tapered recess of the bottom plate of the hollow structure, thus eliminating the need for adhesive fastening.

Abstract: Although MIM (metal injection molding) has received widespread application, aluminum has not been widely used for MIM in the prior art because of the tough oxide layer that grows on aluminum particles, thus preventing metal-metal bonding between the particles. The present invention solves this problem by adding a small amount of material that forms a eutectic mixture with aluminum oxide, and therefore aids sintering, to reduce the oxide, thereby allowing intimate contact between aluminum surfaces. The process includes the ability to mold and then sinter the feedstock into the form of compacted items of intricate shapes, small sizes (if needed), and densities of about 95% of bulk.