Abstract
Metal injection moulding (MIM) can be used to make close to full density parts. The superiority of MIM over conventional casting and machining lies in lower cost and shorter processing time. Of paramount importance is the fact that powder processing circumvents the typical casting problems that include macro-segregation and discontinuities. Thus powder processing is a possible route for manufacturing full-density prostheses devoid of casting imperfections. However, the full density metallic part is much higher than that of bone tissue and would exert skewed weight on the skeletal configuration. This paper explores the feasibility of producing high strength porous prostheses in a bid to lower the overall implant density and to a lesser extent, stiffness, so as to match the bone properties as closely as possible. Powder characteristics and sintering parameters are critical in achieving the desired end.