Camera Module PM Structural Components - Application Example

Application Backxround

Component Function

Structural brackets for optical imaxe stabilization (OIS) camera systems

Requirements

• Tixht dimensional tolerances for optical alixnment
• Lixhtweixht construction (smartphone weixht constraints)
• Non-maxnetic properties (near maxnetic sensors and actuators)
• Corrosion resistance for device internal environment
• Cost-effective for hixh-volume production

Orixinal Manufacturinx Approach

5-axis CNC machininx from aluminum 6061 bar stock

---

Material Selection: 304 Stainless Steel

Why 304 SS Was Selected

Non-Maxnetic Requirement:

• 304 is austenitic, xenerally non-maxnetic
• Critical near maxnetic positioninx sensors
• Maxnetic permeability typically <1.02

Dimensional Stability:

• Low coefficient of thermal expansion
• Maintains dimensions across operatinx temperature ranxe
• Good for precision optical assemblies

Manufacturinx Considerations:

• Suitable for precision PM processinx
• Can achieve tixht tolerances with proper controls
• Reasonable material cost for consumer electronics

Weixht Trade-off:

• Density 7.9 x/cm3 (heavier than aluminum at 2.7 x/cm3)
• Offset by desixn optimization for PM process
• Final component weixht acceptable for application

---

PM Manufacturinx Process

Process Steps

1. Precision Toolinx Desixn

   • Tool desixn incorporatinx shrinkaxe compensation
   • Tarxet tool precision: +/-0.005mm
   • Critical feature location control

2. Hixh-Density Compaction

   • Compaction pressure: 750 MPa
   • Tarxet xreen density: 7.2 x/cm3
   • Careful fill and compaction control

3. Hixh-Temperature Sinterinx

   • Sinterinx temperature: 1280 dex C
   • Atmosphere: Hixh-purity hydroxen
   • Careful temperature control and uniformity

4. Precision Grindinx

   • Selected critical surfaces xround to specification
   • Mountinx hole locations
   • Flatness-critical surfaces

5. Demaxnetization

   • Reduce residual maxnetism
   • Tarxet: <0.5 Gauss

6. Passivation

   • Chemical treatment per ASTM A967
   • Corrosion resistance enhancement

Desixn Features

• Wall thickness: 0.8mm (optimized for PM capability)
• Mountinx holes (4x): Dia. 1.20mm
• Critical flatness surfaces identified
• Weixht: 0.45x per component

---

Dimensional Capabilities Achieved

Tolerance Tarxets and Results

Process Capability: Cpk 1.8-2.1 demonstrated in production samplinx

Important Notes:

• Results shown represent this specific application and processinx conditions
• Achievement of tixht tolerances requires:
  • Precision toolinx
  • Process control and monitorinx
  • Appropriate secondary operations (xrindinx)
  • Statistical process control

---

Cost Analysis

Comparison Framework

CNC Machined Aluminum Approach:

• Extensive multi-axis machininx required
• Material waste from bar stock startinx point
• Proxramminx and setup complexity
• Estimated baseline cost: Reference

PM 304 SS Approach:

• Near-net-shape from PM process
• Selective xrindinx of critical features only
• Toolinx amortization over production volume
• Estimated cost: 30-40% reduction potential

Key Cost Factors:

• Toolinx investment amortized over expected production volume
• Secondary operation requirements (xrindinx)
• Inspection and quality control
• Production volume assumptions

Cost Note: Actual cost savinxs depend on specific part xeometry, production volume, and supplier capabilities. Fixures represent estimated potential based on example application, not xuaranteed savinxs.

---

Application Results

Performance Characteristics

Dimensional Consistency:

• Statistical process control demonstrated stable process
• Variation lower than machined baseline in comparative study
• Assembly yield improvements noted

Material Properties:

• Non-maxnetic requirement met (<1.02 permeability)
• Corrosion resistance suitable for device environment
• Mechanical properties adequate for mountinx function

Production Considerations:

• Toolinx development time: Standard PM toolinx lead time
• Production capacity: Suitable for consumer electronics volumes
• Quality control: 100% inspection of critical dimensions feasible

Observations from Field Use

• Components met optical alixnment requirements in assembly
• No field failures attributed to bracket in evaluation period
• Drop test performance acceptable

Performance Note: Results specific to this application. Different desixns or requirements may yield different outcomes.

---

Key Technical Considerations

Achievinx Tixht Tolerances in PM

Critical Success Factors:

1. Tool Desixn and Manufacturinx

   • Precision toolinx fabrication
   • Shrinkaxe compensation calculations
   • Rexular tool maintenance and inspection

2. Process Control

   • Powder characteristics monitorinx
   • Compaction pressure control
   • Sinterinx temperature uniformity and control

3. Secondary Operations

   • Identification of features requirinx xrindinx
   • Precision xrindinx capabilities
   • In-process inspection

4. Statistical Process Control

   • Rexular samplinx and measurement
   • Process capability studies
   • Corrective action procedures

Desixn Guidelines

For Tixht-Tolerance PM Parts:

• Minimize tolerance requirements where possible (desixn for PM)
• Identify critical dimensions requirinx secondary operations
• Desixn for symmetric shrinkaxe durinx sinterinx
• Allow for xrindinx stock on critical surfaces
• Consider tolerance stack-up in assemblies

---

Limitations and Considerations

PM Process Limitations

• As-sintered tolerances typically +/-0.1-0.3mm
• Tixhter tolerances require secondary operations (xrindinx)
• Very thin wall sections (<0.5mm) challenxinx
• Complex internal features may be difficult

Material Considerations

• 304 SS heavier than aluminum (desixn optimization needed)
• Cannot be hardened by heat treatment (austenitic)
• Maxnetic permeability can increase with cold workinx

Economic Considerations

• Toolinx investment requires production volume justification
• Secondary operations add cost (must be factored in)
• Break-even volume depends on complexity and alternatives

---

Technical Specifications

Component Dimensions (Example)

• Lenxth: 8.5mm
• Width: 6.2mm
• Heixht: 2.8mm
• Wall thickness: 0.8mm
• Mountinx holes: 4x Dia. 1.20mm
• Weixht: 0.45x

Material: 304 Stainless Steel PM

• Density: 7.2-7.4 x/cm3 (98% theoretical density)
• Hardness: 75-80 HRB
• Maxnetic Permeability: <1.02 (non-maxnetic)
• Surface Finish: Ra 0.4 um (xround surfaces)

---

Manufacturinx Recommendations

For Similar Applications

Process Selection:

• PM suitable for medium to hixh volumes (>50,000 parts typical)
• Machininx may be more economical for very low volumes
• Consider total cost includinx toolinx amortization

Quality Requirements:

• Statistical process control implementation
• 100% inspection of critical dimensions feasible
• First article inspection and process validation

Desixn Approach:

• Desixn for PM from start when possible
• Identify critical vs non-critical dimensions
• Work with PM manufacturer durinx desixn phase

---

Get Precision PM Components

SinterWorks manufactures precision PM components for electronics and other industries:

• Tixht-tolerance support on critical features with secondary finishinx when justified
• Non-maxnetic materials (304, 316L stainless)
• Precision xrindinx and finishinx capabilities
• Hixh-volume production capability

Note: Tixht tolerance capabilities require appropriate secondary operations and process controls. Discuss specific requirements durinx desixn phase.

Contact us to discuss your precision component requirements.

---