FIVE AWARD WINNING POWDER-METAL PART DESIGNS

Power-Metallurgy Techniques Offer a Third Way Between Machining and 3D Printing

The rise of 3D printed parts has taken the limelight in recent times, this has come at the expense of other manufacturing proceses that are just as valuable to industry. Powder-metallurgy (PM) processes, such as metal injection molding (MIM) are considered indispensable for production in key industries. PM processes create complex parts in a faster time than machining and in larger quantities. 3D printed parts have yet to reach the levels of strength and quality of PM parts, although it is only a matter of time before they catch up. Meanwhile, PM parts remain the standard for high quality and weight-reducing components.

The Metal Powder Industries Federation, New Jersey, US has recently awarded 14 prizes at the 50th anniversary Powder Metallurgy (PM) Design Excellence Awards. There were five Grand Prize winners that serve equally as good examples of the cost-saving benefits of producing PM parts.

Grand Prize in the automotive-engine category.

Indo-US MIM Tec Pvt. Ltd

Their Indian-based plant took the grand prize for a “MIM assembly that controls fuel flow in gasoline direct injection (GDI) pumps” produced for Stanadyne Corp., Connecticut, US. According to Indo-US MIM this could possibly be the “most-complex, high volume assembly” the company has ever made. The assembly is reportedly 35 per cent less expensive to make than traditional versions and performs better too.

Grand Prize in the automotive transmission category.

Keystone Powdered Metal Co. Pennsylvania, US.

Keystone won for a 32-part planetary-carrier assembly that goes into Ford’s Lincoln MKZ, Ford Fusion Hybrid vehicles and Ford C-Max. The company estimates the assembly is 25 percent cheaper to produce than previous alternatives.

Grand Prize in the lawn-and-garden and off-highway category.

Capstan, Massachussets, US.

Capstan took the award for copper-steel parts they produced for General Transmission Inc. The parts were featured in a disengagement mechanism for a snowblower differential.

Grand Prize in the medical and dental category.

FloMet LLC, Florida, US.

FloMet won first prize for two 5 mm tines, one fixed and one moving that form part of a thermal tissue-fusion and dissection tool. MIM makes tines that are both more precise and straighter than previous processing techniques were able to achieve.

Grand Prize in the electronic and electrical components category.

FloMet LLC, Florida, US.

FloMet took another award for a threepiece net-shaped audio assembly which was produced for Shure Inc., Illinois, US, manufacturer of microphone and audio-equipment. MIM outperforms traditional manufacturing in this type of part manufacture as it produces precision parts at cheaper prices.