Key Features:
- High-temperature resistance up to 1600°C
- High density (3.9 g/cm³) and zero open porosity prevent chemical sticking and metal contamination
- Outstanding planarity and dimensional stability during severe sintering shrinkage
- High compressive strength (3300 MPa) and superior wear resistance
- Comprehensive range of standard sizes and thicknesses (2 mm, 3 mm, 4 mm, 5 mm, etc.)
- Customization available for holes, gas-permeable grooves, and part-positioning pockets
Product Overview
Metal injection molding (MIM) produces small, complex metal components through injection molding, debinding, and sintering. During the final high-temperature sintering stage, green parts densify and undergo significant volumetric shrinkage.
Ceramic setter plates provide an ultra-flat, non-reactive refractory surface for arranging parts inside the furnace. They remain in direct contact with MIM components throughout thermal ramp-up and shrinkage. Plate dimensions, flatness, thickness, and surface roughness are critical to preventing part warping, drag distortion, and chemical sticking.
Common Sizes of 99% Alumina Setter Plates
2 mm Thickness Plates
| Dimensions (L × W × T) | |
|---|---|
| 75 × 175 × 2 mm | 125 × 145 × 2 mm |
| 90 × 120 × 2 mm | 125 × 160 × 2 mm |
| 90 × 130 × 2 mm | 150 × 150 × 2 mm |
| 100 × 100 × 2 mm | 150 × 180 × 2 mm |
| 100 × 120 × 2 mm | 150 × 200 × 2 mm |
| 100 × 135 × 2 mm | 180 × 180 × 2 mm |
| 100 × 150 × 2 mm | 180 × 300 × 2 mm |
| 110 × 110 × 2 mm | 200 × 300 × 2 mm |
| 110 × 140 × 2 mm | 220 × 220 × 2 mm |
| 125 × 135 × 2 mm | — |
Other Thickness Plates
| Dimensions (L × W × T) | |
|---|---|
| 166 × 93 × 2.6 mm | 175 × 125 × 4 mm |
| 135 × 125 × 3 mm | 130 × 90 × 5 mm |
| 150 × 150 × 3 mm | 139.5 × 139.5 × 6.58 mm |
| 100 × 100 × 3.5 mm | — |
Plate size and thickness should be selected based on the MIM component footprints, loading weights, and internal furnace dimensions. In addition to standard sizes, INNOVACERA provides tailored dimensions, precision surface grinding, and positioning features according to your engineering drawings.
Why 99% Alumina for MIM Setter Plates?
INNOVACERA manufactures MIM setter plates using high-purity 99% alumina (Al2O3) due to its exceptional mechanical strength, wear resistance, and thermal durability up to 1600°C.
- Prevents Sticking: Inert chemical properties eliminate diffusion bonding between high-alloy powders (stainless steel, titanium, tungsten-nickel-iron) and the plate.
- Maintains Part Geometry: High hot flexural strength prevents plate sagging under repetitive thermal cycles, guaranteeing part straightness.
- Thermal Consistency: High thermal conductivity ensures uniform heat distribution across furnace heating zones.
Applications in MIM Manufacturing
| Industry | Typical MIM Components |
|---|---|
| Consumer Electronics | Smartphone structural parts, optical brackets, connectors, and hinge components |
| Automotive | Turbocharger vanes, sensor housings, transmission locking parts, and valve components |
| Medical Instruments | Endoscopic forceps, orthodontic brackets, surgical scalpel handles, and precision fittings |
| Industrial & Precision Machinery | Small gears, pneumatic valve bodies, lock hardware, and complex mechanical fittings |
99% Alumina Ceramic Material Properties
| Property | Unit | Value |
|---|---|---|
| Density | g/cm³ | 3.9 |
| Flexural Strength | MPa | 292 |
| Compressive Strength | MPa | 3300 |
| Modulus of Elasticity | GPa | 340 |
| Fracture Toughness | MPa·m¹/² | 3.9 |
| Weibull Modulus (m) | - | 10 |
| Vickers Hardness (HV0.5) | - | 1800 |
| Thermal Expansion Coefficient | 10^-6 K^-1 | 5.0–8.3 |
| Thermal Conductivity | W/m·K | 31 |
| Thermal Shock Resistance | ΔT °C | 250 |
| Maximum Use Temperature | °C | 1600 |
| Volume Resistivity (at 20°C) | Ω·cm | ≥10^14 |
| Dielectric Constant (εr) | - | 10 |
| Open Porosity | % | 0 |
| Dielectric Loss (tanδ) | - | 0.001 |
| Dielectric Strength | kV/mm | 20 |
Need Custom Setter Plates for Your MIM Sintering Furnace?
Please send us your required setter plate dimensions, furnace loading configuration, and MIM alloy details. If you need bespoke nesting pockets, cutouts, or perforated gas holes, provide your engineering drawings. INNOVACERA will review your technical parameters and provide an OEM quotation.
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Frequently Asked Questions
Why Use 99% Alumina Setter Plates for MIM Sintering? How Do They Prevent Part Distortion?
During the high-temperature densification stage of Metal Injection Molding (MIM), metal powders shrink by 15–20%. Any friction, uneven thermal expansion, or chemical reaction with the kiln furniture causes severe warping, drag lines, and cracking. INNOVACERA’s 99% alumina setter plates provide diamond-ground planarity, extreme compressive strength (3300 MPa), and zero open porosity. Operating reliably up to 1600°C, they eliminate diffusion sticking with molten alloys and allow smooth, uniform part contraction without drag-induced distortion.
Need Custom Grooves or Pierced Holes for Sintering Trays? How to Order Custom MIM Setter Plates from INNOVACERA?
In addition to standard 2 mm to 6.58 mm flat rectangular plates, INNOVACERA provides full custom ceramic setter plate manufacturing. Customers can specify plate profiles, pre-machined part-nesting pockets, gas circulation holes, and positioning pins to match automated furnace loading tracks. Simply submit your sintering furnace dimensions, MIM part alloy specifications, and temperature cycle curves to receive technical review and quotation.
