Manufacturers evaluating powder metallurgy often come in with the same questions.
They want a clear picture of how the process works in practice and where opportunities and challenges tend to appear as a design moves forward. When those answers are clear early on, teams can move faster, avoid design changes, and avoid potential issues..
Many explanations of the powder metallurgy process remain at a high level.. While they cover the basics, they don’t often extend to the practical decisions engineers and sourcing teams need while a part is still under review.
In Episode 11 of the PM Blend podcast, Atlas experts walk through the powder metallurgy process by responding to the questions they hear most often during customer conversations. Those questions tend to surface early, long before a part reaches production.
The powder metallurgy process forms metal parts by pressing powdered material into compacts and then heating them to bond the particles together. Rather than cutting material away, the part’s geometry is created inside a tool during the compaction process.
In conventional powder metallurgy, the compacted part is conveyed through a furnacewhere heat bonds the particles without fully melting the metal. After sintering, the part has the strength needed for handling, assembly, or secondary operations.
At a high level, the process follows a consistent path:
Powder is compacted into a net or near-net shape
Heat bonding occurs during sintering
This approach is why powder metallurgy is often considered when teams want to limit machining or rethink how a part is manufactured early in the design phase.
Once powder metallurgy is selected, attention turns to how a part moves through production. While the overall flow stays consistent, material choice and geometry determine how each step is handled.
Production begins at the press. Powder is loaded into a die cavity and compressed using upper and lower punches. At this stage, the part holds its shape but remains fragile and needs controlled handling.
During compaction:
After pressing, parts move through a furnace. Heat allows the powder particles to bond without fully melting the metal. This step gives the part its strength and dimensional stability.
Temperature ranges discussed in the episode include:
|
Material type |
Typical sintering range |
|
Iron alloys |
Around 2000°F |
|
Bronze and brass |
Around 1500°F |
|
High temperature materials |
Above 2100°F |
After sintering, parts may ship as produced or require secondary operations based on their end-use requirements
Powder metallurgy often comes into focus when teams begin questioning long-standing manufacturing choices. When a part requires extensive machining just to reach its basic shape, it can signal that there may be a more efficient way to produce it.
One of the biggest shifts is how material is used. Instead of cutting away large portions of metal, powder metallurgy forms the part’s geometry inside the tool. That change alone can influence how teams think about waste, consistency, and overall production effort.
There is also a level of confidence that comes with forming parts this way. Once tooling is properly dialed in, parts come off the press quickly and with repeatable results. For programs that depend on steady output and predictable performance, that kind of consistency is difficult to ignore.
Tooling is one of the first topics that comes up when teams start evaluating powder metallurgy. Part geometry, material choice, and the design stage all help determine what makes sense early on.
A basic powder metal tool consists of a die with upper and lower punches. As part complexity increases, tooling may incorporate features such as core rods or multiple pressing levels. These allow more geometry to be formed during pressing, but they also influence tool life and overall cost.
Tool life varies based on factors discussed in the episode:
Part geometry and face detail
Density distribution across the shape
Powder behavior under pressure
Most powder metal tools are single-cavity, since press speed often supports required production volume without the need for additional cavities.
Prototyping typically follows one of two paths:
Tooling-based prototypes
Use production-style tooling
Often transition directly into production
Machined puck prototypes
Used for small quantities
Helpful when designs or materials are still evolving
The decision usually depends on how stable the design is at the time.
Part size is often less about physical dimensions and more about press capacity. In the episode, the team explains that surface area drives tonnage requirements faster than most people expect. In many cases, a part will reach a press limit before it looks “too big” on paper.
Atlas operates presses across a wide tonnage range, which provides flexibility, but design still plays a critical role. Internal features can reduce surface area and lower tonnage needs, while thin walls or complex levels increase overall pressure demands on the tooling
Conversions are where powder metallurgy often demonstrates its value.
Machined part conversions
Replace long machining cycles with pressed features
Mold teeth, splines, or forms instead of cutting them
Shorten cycle time once tooling is in place
Casting conversions
Hold tighter dimensional control
Reduce or eliminate the need for draft
Improve consistency across production runs
Another factor that often emerges in conversion discussions is part consolidation. In some cases, powder metallurgy allows multiple components to be combined into a single pressed part, which simplifies assembly and reduces handling.
These considerations tend to surface as teams evaluate part size, geometry, and how the component fits into a larger assembly.
Porosity is a built-in characteristic of powder metallurgy, and in many applications it is used intentionally. One common example discussed in the episode is self-lubricating bearings. After pressing and sintering, these parts are sized and then impregnated with oil. During operation, heat draws oil to the surface. As the part cools, oil is pulled back into the pores.
Wall thickness directly affects how much lubricant a part can retain. Reducing material too aggressively can limit performance and introduce maintenance requirements that were not part of the original design. In some cases, alternative materials or grease impregnation may be considered depending on operating conditions.
Steam treating: This process uses heat and steam to form an oxide layer on the surface. The result is a darker finish with improved wear behavior and added surface protection.
Copper infiltration: Copper melts during sintering and is drawn into the part through capillary action. This fills internal pores and raises overall part strength.
Welding powder metal parts: Powder metal parts are welded in many applications. Clean handling is important, since contaminants trapped in pores can create issues during welding.
Several factors tend to have the greatest impact when cost is discussed:
Machining often contributes the most to overall cost. Geometry and density directly influence tooling wear and press behavior over time. At lower production volumes, setup time becomes more significant, even in cases where powder metallurgy remains competitive.
Questions about the powder metallurgy process often come up early, before a design is finalized or tooling decisions are made. Addressing those questions at that stage gives teams a clearer path forward and reduces changes once production is underway.
Understanding how the powder metallurgy process works in real manufacturing settings provides engineers and sourcing teams a stronger foundation for evaluating fit, cost, and long-term performance with confidence. That clarity supports better informed decisions and more predictable outcomes as a program moves into production.
Prefer audio? Episode 11 of The PM Blend covers these topics in conversation.
If you want to talk through a specific part or design, the Atlas team is ready to help.