Custom Metal Injection Molding Services
At The Federal Group USA, we provide high-volume metal injection molding solutions for small, complex parts—helping you reduce costs, simplify designs, and scale production with confidence.
From tooling through production, logistics, and warehousing, we manage the entire process to ensure a seamless, reliable supply chain.
Request a QuoteWhy Choose TFG for MIM Services
Diverse Materials
17-4 PH, 316L stainless, low alloy steels, and specialty alloys to meet strength and corrosion requirements.
Advanced Technology
Precision tooling, controlled debinding, and high-temperature sintering for consistent, complex parts.
Quality Assurance
In-process inspections and final validation to ensure dimensional accuracy and material performance.
Tight Tolerances
Near-net shape parts with typical tolerances of ±0.3%, minimizing secondary machining.
Industry Applications: Diverse Sectors We Serve
The Federal Group USA provides custom metal injection molding solutions for a wide range of industries, helping clients overcome the challenges of producing small, complex components at scale. From medical and consumer products to electronics, our expertise in the MIM process ensures parts are engineered for precision, performance, and cost efficiency in demanding applications.
Medical Components
The Federal Group provides advanced metal injection molding services for the medical industry, producing small, high-precision components such as surgical instruments, orthopedic device parts, dental tools, and minimally invasive device components where tight tolerances, biocompatibility, and corrosion resistance are critical.
Consumer Products
We manufacture precision hardware, and appliance parts such as gears, actuators, latches, and structural components using MIM, enabling complex geometries and consistent quality at high volumes.
Electronics
The Federal Group produces connectors, housings, shielding components, and micro-mechanical parts through MIM, delivering fine detail and repeatable performance at scale.
MIM Tolerances & Specifications
Metal injection molding is designed to deliver consistent, high-precision components at scale, with predictable dimensional control and material performance.
- Dimensional Tolerances: ±0.3% of nominal dimension is standard, with tighter tolerances achievable on critical features through secondary operations.
- Density: Typically 95–99% of wrought material, providing strong mechanical properties suitable for demanding applications.
- Surface Finish: As-sintered surface finishes typically range from 32–125 microinches, with finer finishes available through secondary processing.
- Part Size & Weight: Best suited for small, complex components, generally under 100 grams, depending on geometry and material.
- Production Volume: Ideal for mid- to high-volume production, where tooling investment is offset by low per-part cost.
Secondary Operations & Finishing
While metal injection molding produces near-net shape components, secondary operations can be applied to meet specific performance, cosmetic, or dimensional requirements.
At The Federal Group USA, we offer a range of value-added services to ensure your parts are fully finished and production-ready:
- Heat Treating: Enhance strength, hardness, and wear resistance based on your application requirements.
- Surface Finishing: Options such as polishing, tumbling, and blasting to achieve the desired surface appearance and texture.
- Plating & Coating: Improve corrosion resistance, conductivity, or aesthetics with finishes like nickel plating, black oxide, or PVD coatings.
- Precision Machining: Tighten critical tolerances, add threads, or refine features where additional precision is required.
- Assembly & Kitting: Streamline your supply chain with fully assembled or packaged components ready for integration.
The Federal Group’s Metal Injection Molding Capabilities
Metal injection molding is an excellent way to produce complex shapes and components with maximum efficiency and scalability. If you’re interested in utilizing metal injection molding to produce a new product or component, we’d be happy to help you navigate the process.
The Federal Group USA can help you design your mold, select the appropriate materials, and guide you through each step of the MIM process. We’ve helped clients in a wide array of industries ranging from medical to construction.
If you’d like to request a free, no-obligation quote or speak with one of our experienced sales team members, send us an email or give us a call at (800)759-2658.
Client Testimonials
Trustindex verifies that the original source of the review is Google.
Jonathon Lanham2025-09-26Mike Allen and The Federal Group have been an absolute pleasure to work with. From the first day we reached out to them they responded punctually and professionally and helped us with every step of the process. We came to them with a budget conscious challenge and they delivered above and beyond a fitting and accurate solution. A quality finished part that has improved the overall quality of our product, and that's what really counts. Thank you to The Federal Group!Trustindex verifies that the original source of the review is Google.Sean Brockhouse2025-04-20Sandor Holzer has gone above and beyond helping us to get another part ramped up for production, creative getting samples ahead of schedule so we could meet tight timelines. Outstanding customer service!!Trustindex verifies that the original source of the review is Google.Melissa Quiroz2024-08-09Good company, knowledgeable staff, product was exactly what i asked for. Got me out of a jam!Trustindex verifies that the original source of the review is Google.Alex Armstrong2023-12-15Steve was great to work with and was always available when needed.Trustindex verifies that the original source of the review is Google.Jon Ramsey2023-10-07Mike at TFG was tenative to our supply needs and an immense help! Took on a project that was quite large and daunting, only to be resilient through the task challenges. In conclusion, everything was completed successfully and a huge success. Would recommend and I plan to use them for future projects. Thanks again Mike and TFG team.Trustindex verifies that the original source of the review is Google.Nic Robinson2023-10-05Steve Bogdanovich has been critical to our team meeting deadlines with a quality product. The communication and customer service is top notch. We know we can rely on Steve and The Federal Group team to get us a quality product and in a timely manner. We've sent all of our casted parts through them because we know we will get the best service, and they keep us informed through every step in the process.Trustindex verifies that the original source of the review is Google.Sean Connelly2023-06-21The Federal Group was great to work with. Steve was very professional and diligent in providing good advice/feedback as well as following up with me. Look forward to working with them in the future as well!Trustindex verifies that the original source of the review is Google.Sher Stahl2020-07-10The Federal Group is a top-notch supplier of ours. They take quality very seriously and strive to ensure we have exactly what we want and when we need it. Communication is excellent. Service is excellent. I have worked with this supplier directly for better than 7 years now, and still considered one of my best suppliers. We've recently expanded our product line with this company and are excited to partner on this line and on future projects. Words cannot express how grateful I am to have such a responsive company, and rep, Richard, to work with. I highly recommend this supplier.Trustindex verifies that the original source of the review is Google.Marshall2020-06-30Excellent customer service and products!
