Is your team spending too much time machining, assembling, or troubleshooting metal parts that just aren’t quite right?
For many manufacturers, legacy designs and multi-part assemblies create hidden inefficiencies. That’s why more companies are turning to process conversions — rethinking how parts are made, consolidated, and optimized using the latest powder metal technologies and applications.
Your manufacturing supplier should do more than produce components — it should actively partner with your team to discover innovative and smarter ways to design them. From collaborative engineering design meetings to on-site line walks, process improvement is built around asking the right questions and finding the most effective answers.
From Line Walks to Redesigns: See Powder Metal in ActionDo you want to know how a component vendor thinks through part conversions in the real world? Atlas experts Mark Powell and Joe Pfingstler explore powdered metal conversions in an engaging, behind-the-scenes discussion of The PM Blend podcast. You’ll hear how we walk the production line and what makes a good (or bad) PM candidate. It’s a great example of how sales and engineering teams work together to identify the most practical and cost-effective path to production. Watch the episode now: |
Powder metallurgy (PM) isn’t a new process, but it’s still underutilized across many sectors. At its core, PM is about producing net-shape or near-net-shape components by compressing metal powders into dies and sintering them at high temperatures. Powder metal components aren’t just cost-effective — they’re also built for performance, repeatability, and simplified production.
Here are some reasons why manufacturers explore the application of powder metallurgy in their processes:
Most powder metal projects don’t start with a CAD model — they begin with a question:
These types of questions often spark deeper conversations between teams. Initial discussions typically involve your engineering or procurement teams, followed by a technical evaluation with Atlas’s engineering staff to assess feasibility and performance requirements.
The goal is to ensure all stakeholders clearly understand the part’s function, constraints, and potential for improvement within the broader manufacturing system. This close collaboration is essential to identifying practical applications that align with your design, performance, and production goals.
One of the most valuable tools in your toolkit isn’t a machine — it’s a line walk. By visiting your facility and observing your production floor, we can spot challenges and opportunities that don’t appear on part drawings.
During a line walk, a part supplier may notice:
If a group of parts is always used together and never disassembled, it may present an opportunity to redesign them as a single powder metal component.
In the right situation, powder metal conversions allow for reduced fastener use, easier assembly, and fewer SKUs — all while maintaining or improving functional performance.
A full-service powder metallurgy manufacturer will review potential conversions and part designs using both business and technical criteria:
Can the shape be compacted and ejected from a die? Are there any features — such as undercuts or threads — that would require alterations to allow forming within the tool or additional secondary operations?
Does the application require strength, wear resistance, corrosion resistance, or lubrication? We’ll select the right alloy and density for your needs, and explain how it impacts each stage of the powder metal manufacturing process.
Will the part be bolted, press-fit, or welded? Will it run through a paint line? We’ll design for both part performance and the environment in which it operates.
Because PM tooling carries an up-front investment, we consider annual usage to determine ROI. For most parts, medium- to high-volume production is the sweet spot for PM efficiency.
One misconception is that your part design needs to be PM-perfect out of the gate. Not true.
Our engineers often recommend minor design adjustments — like smoothing corners or modifying bosses — that make a component suitable for powdered metal without sacrificing performance.
These tweaks can lead to:
Want to see how this collaboration plays out in real manufacturing environments? Here are two real-life conversion projects that helped simplify production and improve outcomes.
An appliance manufacturer sought to improve a hinge used in a roller assembly. The original design involved laminating three stamped stainless steel pieces, aligning them precisely, and riveting them together to achieve the necessary thickness. This process was labor-intensive and posed challenges in maintaining consistent quality and functional aesthetics.
Challenges Identified:
After reviewing the application, a powder metal manufacturer proposed a fully integrated powder metal hinge — one part instead of three.
The result:
Looking at the hinge as a functional unit — not three isolated parts — simplified the customer's process and delivered an improved product.
A hand tool manufacturer aimed to enhance a component's design, performance, cost-efficiency, and assembly time. The original subassembly comprised three separate parts: a stamped sprocket, a machined lower body, and a fastener. This configuration necessitated multiple manufacturing processes and assembly steps, increasing labor and production costs.
Challenges Identified:
A powder metal manufacturer converted the three-part subassembly into a single, multi-level, net-shape powder metal component. This conversion allowed for:
Results Achieved:
This was a perfect example of how powder metallurgy part manufacturing can enhance a component.
These are only two examples of how powder metal conversion can improve manufacturing outcomes. In both examples, Atlas Pressed Metals helped unlock more accurate and streamlined production by doing more than just quoting the part. We asked the right questions, brought engineering and sales together, and looked at how the part functioned in context — not just how it was made.
We’re not here to sell you powdered metal at all costs.
We’ll tell you if your part isn’t a good candidate — whether due to geometry, low volume, or assembly needs. We will work with you to see if another part of your system might be a better fit.
Our goal isn’t to push powdered metal. It’s to use it strategically to help you manufacture smarter.
When you work with Atlas, you’re not just getting a part — you’re investing in an entire manufacturing thought process. That’s the real premise of powder metal technology and its ever-growing range of applications.
From reducing part count, simplifying assembly, improving quality, and reducing cost, powdered metal can support your:
And because we operate as a collaborative powder metallurgy manufacturer, we’re here to work with and guide your team — from initial evaluation to final implementation.
Looking to make your next part a strong candidate for powder metallurgy? Our free Powder Metal Design Guide walks you through best practices, material considerations, design tips, and more — all to help you maximize performance and cost-efficiency from the start.
Download the Design Guide and start designing smarter with powdered metal today: