Case Studies
Every powder metallurgy project starts with the same question: can this part be made better, cheaper or lighter? The cases below show how we answered it for four very different customers. Figures are representative of typical outcomes on similar programmes.
Case 1 – Replacing a Machined Transmission Gear
Industry: Automotive | Part: Helical transmission gear | Volume: 1.2 million pieces per year
The challenge
A tier-one supplier was machining a helical gear from forged steel bar. Material utilisation was under 50%, the part needed four machining operations plus broaching, and the cost target for the next vehicle platform could not be met.
What we did
- Redesigned the part for powder metallurgy with the helix formed directly in the compaction die
- Selected a diffusion-alloyed steel with vacuum carburising for tooth surface hardness
- Applied sizing on the bore and tooth profile to meet the accuracy specification
- Validated the part through a full PPAP, including gear rolling inspection and fatigue testing
The result
- 34% lower unit cost versus the machined design
- Material utilisation improved from 48% to 93%
- Two machining operations eliminated entirely
- No change required to the customer’s assembly process
Case 2 – Harmonic Drive Flexspline for a Collaborative Robot
Industry: Robotics | Part: Flexspline cup | Volume: 45,000 pieces per year
The challenge
A robotics customer needed a thin-walled flexspline with fine tooth geometry and high fatigue strength. Machining the part was expensive and created inconsistency between batches.
What we did
- Produced the cup by metal injection molding in a low-alloy steel, reaching near-full density
- Developed a custom heat treatment cycle to control distortion and maximise fatigue life
- Finished the teeth by precision machining to the customer’s transmission specification
- Introduced 100% tooth inspection on critical parameters
The result
- 22% cost reduction against the machined baseline
- Batch-to-batch dimensional variation cut by more than half
- Fatigue life verified to exceed the customer’s 10,000-hour requirement
- Stable supply supporting the customer’s ramp-up in production
Case 3 – Chainsaw Drive Sprocket for Outdoor Power Equipment
Industry: Agricultural & Gardening | Part: Chain drive sprocket and clutch drum | Volume: 2.5 million pieces per year
The challenge
An outdoor power equipment brand needed a sprocket that would survive constant chain wear, impact loading and humid storage – at a consumer-product price point.
What we did
- Formed the complete sprocket profile, including the hub and lightening holes, directly in the die
- Selected a high-carbon sintered steel with through-hardening plus steam treatment for wear and corrosion resistance
- Combined the sprocket and clutch drum features into a single sintered part
- Set up automated pressing with weight and density control for high-volume consistency
The result
- 41% lower unit cost than the previous two-piece machined assembly
- Part count reduced from two to one, removing an assembly operation
- Chain wear life equal to or better than the previous design in field testing
- Reliable supply at 2.5 million pieces per year
Case 4 – MIM Connector Shell for an Electronics Customer
Industry: Electronics | Part: Shielded connector shell | Weight: 3.8 g | Volume: 6 million pieces per year
The challenge
A customer was machining small stainless connector shells from bar stock. Wall thickness was 0.6 mm, scrap rates were high, and demand growth outpaced their machining capacity.
What we did
- Converted the part to metal injection molding in 316L stainless steel
- Redesigned the part with MIM-friendly features while keeping the customer’s interface dimensions unchanged
- Developed a debinding and sintering cycle that held flatness and roundness within specification
- Added a vibratory finishing step to achieve the required cosmetic surface
The result
- 52% lower unit cost versus machining
- Scrap reduced from 18% to under 2%
- As-sintered finish good enough to skip the polishing operation
- Capacity available for continued volume growth
What Could We Save You?
Send us the part you are currently machining or casting, along with your annual volume. We will run a free manufacturability assessment and tell you honestly whether powder metallurgy would help – and by how much.