Award: Grand Prize
Year: 2005
Category: Metal Injection Molding
Market Segment: Household Appliances

Description:
The award was given to highly complex electrical connectors used in a plug and adaptor. The unique part is made from copper powder to a density of 8.8 g/cm³. It has an ultimate tensile strength of 36,000 psi and a yield strength of 8,700 psi, and an elongation of 45%. The electrical plug and adaptor that contains the MIM copper connectors is a new product used in the electrical appliance industry. The plug is ergonomically designed to make direct contact with the power track. The cover of the plug is made of polycarbonate. The plug can be engaged anywhere along the power track, which allows users to continue to use their existing three-pin plugs. The MIM copper has better electrical performance compared to brass. Using a MIM copper part replaced processes such as stamping, turning, machining, and press-fitting, offering the customer a cost savings of more than 20%.