Closing the Loop: How CT Scanning Improves MIM Tooling and Part Design

Small flaws in metal injection molding don’t stay small for long. A microscopic void or a fraction of a millimeter in shrinkage can throw off part performance, disrupt assemblies, or stall production entirely. For manufacturers chasing tight tolerances and high yields, these imperfections aren’t just costly—they’re hidden threats. This article explores how industrial CT scanning uncovers both external and internal discrepancies in MIM parts, and more importantly, how that data can be fed back into the design and tooling process to streamline production, reduce waste, and improve part quality from the inside out.

Industrial CT scanning for MIM becomes more than just a quality check—it's a tool for continuous improvement. By leveraging detailed CT scan data, MIM companies can “close the loop” between production and design, refining their tooling and component geometry for better outcomes.

Bridging the Gap Between As-Designed and As-Manufactured

No matter how precise the simulation, there is always a gap between what is designed in CAD and what emerges from the mold. MIM parts undergo complex transformations—from metal powders to sintered components—introducing opportunities for distortion, shrinkage variation, and internal anomalies.

Industrial CT scanning for MIM components provides a direct comparison between the as-designed and as-manufactured part, allowing engineers to visualize deviations and pinpoint inconsistencies:

• Warping or sink marks due to uneven shrinkage
• Short shots or incomplete fill in tight cavities
• Internal voids or porosity from gas entrapment
• Tool wear artifacts over time

This non-destructive insight means issues can be traced back to their root cause—whether it’s mold design, process parameters, or material behavior—without cutting a single part open.

Tooling Optimization: Adjust with Confidence

For toolmakers, CT scanning for MIM tooling optimization removes the guesswork. Instead of relying on surface metrology alone, CT scanning gives a complete 3D volumetric view of the part, allowing for accurate mold compensation:

• Shrinkage compensation: Measure actual shrink rates and modify cavity dimensions accordingly
• Flash detection: Identify and correct venting or parting line issues early
• Undercuts and draft angles: Verify tool accessibility and part release
• Thin-wall consistency: Ensure critical cross-sections mold correctly and fully

The ability to iterate tooling based on data—not assumptions—can accelerate time-to-production and reduce costly trial-and-error cycles.

Design Feedback: Real-World Validation of Geometry

CT scanning also supports the part design process. When the scanned model is overlaid on the CAD file, engineers can see how real-world conditions affect part geometry and performance. This leads to better-informed design decisions such as:

• Reinforcing thin sections that tend to deform or shrink unevenly
• Rounding sharp corners prone to stress concentrations
• Adjusting tolerances based on actual process variation

The result is a smarter, more robust part design that’s tailored to the realities of metal injection molding, supported by high-fidelity CT data.

A Case for Closed-Loop Engineering

Non-destructive testing for MIM parts isn’t just a tool for detecting problems—it’s a feedback mechanism for preventing them. By integrating CT analysis into the product development cycle, MIM manufacturers can:

• Accelerate first-article inspection and PPAP approval
• Reduce rework and scrap rates
• Improve tool longevity and repeatability
• Achieve better alignment between design and production realities

This is what closed-loop manufacturing with CT scanning looks like: real data, fast insights, and smarter decisions at every step.

Start Closing the Loop with Nel PreTech

At Nel PreTech Corporation, we work with MIM companies to integrate high-resolution CT scanning into their development and production cycles. Our advanced industrial CT systems capture precise 3D data—internally and externally—so you can identify issues, validate tooling, and refine part design with confidence.

Ready to turn inspection into innovation? Get a free quote today or learn more about our CT scanning services for MIM.

For a more in-depth look at CT scanning, download our CT eBook for the Savvy Engineer.