Fine die cast metallic parts

Abstract

A finished molded metal part is produced by an injection molding system includes a feeder in which a metal is melted and a first chamber into which a desired amount of melted metal is introduced. The molded metal parts can have extremely fine dimensions, small thicknesses, and indented or protruding surface features that are molded with such low porosity that no further milling/finishing operation is required before the part is used in its finished state.

1 - 5 . (canceled)  
   
   
       6 . A method of making a molded metal part comprising the steps of: 
 introducing the melted material into a first chamber;    allowing at least a portion of the melted material to pass through said first chamber into a second chamber;    pushing at least a portion of the melted material remaining in the first chamber into said second chamber;    injecting the melted material from the second chamber into the mold; and    forming in the mold the molded metal part, wherein the as-molded surface is sufficiently smooth so that the surface may be painted directly without further processing.    
   
   
       7 . The method of  claim 6 , wherein the molded metal part has a thickness less than 1 mm.  
   
   
       8 . The method of  claim 6 , wherein the thickness is in the range of approximately 0.5 mm to approximately 1.0 mm.  
   
   
       9 . The method of  claim 6 , wherein the molded metal part has dimensions of approximately 21.0 cm by approximately 29.7 cm.  
   
   
       10 . The method of  claim 6 , wherein said allowing step comprises creating a suction in the second chamber to draw the portion of the melted material from the first chamber into the second chamber.