Manufacturing Capabilities

Our Production Process

We control every step of the manufacturing process to ensure the highest quality and consistency.

Powder Metal Parts Process - Step 1 to Step 5

What is the Powder Metallurgy Process?

Powder Metallurgy is a manufacturing technique that transforms metal powders into solid components. Unlike traditional casting or machining, PM utilizes thermal energy and high pressure to bond particles, making it ideal for creating complex shapes with minimal material waste. As a highly efficient metal-forming technology, it has become the go-to solution for industries requiring precision, sustainability, and cost-effectiveness.

The 5 Key Steps of the Powder Metallurgy Manufacturing Flow

Step 1: Metal Powder Production

The quality of the final part begins with the raw material. Common methods include:

  • Atomization: Uses gas or water to break molten metal into fine droplets.
  • Reduction: Extracts pure metal from oxides using chemical reactions.

Step 2: Mixing and Blending

Pure metal powders are mixed with alloying elements (like copper or graphite) and lubricants. This ensures uniformity in chemical composition and reduces friction during the pressing stage.

Step 3: Compacting (Pressing)

The mixture is fed into a precision die and compressed under massive pressure. This creates a "Green Compact"? part that has the final shape but is still held together only by mechanical interlocking.

Step 4: Sintering (The Critical Phase)

The green parts are heated in a controlled-atmosphere furnace to a temperature just below the melting point. This causes atomic diffusion, fusing the particles together to achieve structural integrity.

Step 5: Secondary Operations & Finishing

To meet specific engineering requirements, parts may undergo:

  • Sizing/Coining: For tighter dimensional tolerances.
  • Oil Impregnation: For self-lubricating properties.
  • Heat Treatment: To enhance hardness and wear resistance.

Process Comparison: Conventional PM vs. MIM

Feature Conventional PM Metal Injection Molding (MIM)
Target Industries Automotive, Mechanical, Power Tools Electronics, Robotics, Medical Devices
Complexity Moderate (Best for 2D or simple 3D) Extreme (Complex 3D geometries like plastic injection)
Part Weight Medium to Large (5g to several kg) Micro to Small (Usually under 50g)
Density 85% ??92% 95% ??99% (Comparable to wrought metal)
Surface Finish Good Excellent

Advantages of Powder Metallurgy

Why choose PM over CNC machining or casting? Here are the primary benefits:

  • Near-Net Shape Production: Most parts require zero secondary machining.
  • High Material Utilization: Reduces scrap metal waste by over 95%.
  • Unique Material Blends: Allows for the creation of alloys that are impossible to melt together.
  • Cost-Efficiency: Best suited for high-volume production (Automotive, Aerospace, Medical).

Material Recommendations by Industry

When consulting with clients, recommending the right material can demonstrate your expertise. Here are the common choices:

Automotive & Mechanical

Iron-Copper & Steel Alloys: Used for high-strength gears and structural parts where load-bearing capacity is key.

Power Tools

Nickel Steel (Fe-Ni): Offers excellent toughness and impact resistance to handle high-torque stress.

Electronics & Drones

Stainless Steel (316L, 17-4PH): Provides superior corrosion resistance and a high-quality aesthetic finish.

Robotics & Automation

Diffusion Alloyed Steel: Provides exceptional fatigue strength and impact toughness, ideal for high-load robotic transmission gears.

Hardware & Locks

Brass & Bronze Alloys: Selected for their natural self-lubricating properties and corrosion resistance, perfect for lock cylinders and cams.

Shock Absorber & Hydraulics

Steam Treated Iron: The steam treatment process seals surface porosity, creating gas-tight components with enhanced surface hardness.

Is Powder Metallurgy Right for Your Project?

Powder Metallurgy offers a perfect balance between complexity and cost. If you are looking to mass-produce small, intricate metal parts with high precision and low waste, the PM process is an excellent choice.