For parts that can be made by either process, die casting is typically 2-5x cheaper per part than MIM. This is not inefficiency — it is a fundamental consequence of the process physics.
Cost breakdown — MIM vs die casting (10 g stainless vs 10 g aluminum/zinc):| Cost Factor | MIM (316L Stainless) | Die Casting (Zinc or Aluminum) | Why MIM Costs More |
|---|---|---|---|
| Raw material | $15-25/kg (powder) | $2-5/kg (aluminum ingot), $3-6/kg (zinc) | MIM powder is 3-10x more expensive than casting alloy |
| Cycle time (per cavity) | 15-60 sec (molding) + hours for debind+sinter | 5-30 sec (complete) | Die casting cycle is 10-100x faster |
| Energy cost | High — sintering at 1300°C for hours | Moderate — melting at 400-700°C | MIM sintering is energy-intensive |
| Secondary operations | Minimal — near net shape | Often requires trimming, machining | Die casting parts typically need more post-processing |
The above comparison is misleading in one critical way: MIM uses stainless steel and die casting uses zinc or aluminum. You cannot make an aluminum or zinc part with the strength, corrosion resistance, or temperature capability of MIM 316L. The fair comparison is:
- If you NEED stainless steel: MIM is typically 30-60% cheaper than CNC machining stainless bar stock, and the only alternative for complex geometries
- If you NEED aluminum or zinc: Use die casting — MIM cannot process these materials
MIM costs more per part because: (1) MIM powder costs 3-10x more per kg than die casting alloys, (2) MIM has a much longer cycle time due to debinding and sintering, and (3) MIM sintering is energy-intensive at 1300°C+. However, this comparison is only relevant for the small set of parts that can be made by either process — MIM's primary advantage is producing parts in stainless steel and specialty alloys that die casting cannot work with.