<img src="https://secure.feel2echo.com/260207.png" style="display:none;">
Skip to content
Updated Conversions Webpage Header

Manufacturing Engineering Consulting Services: Powder Metal Conversion

Line

Tired of costly machining, stamping limitations, and inconsistent forged part performance?

If you’re using traditional metal parts manufacturing methods — like casting, stamping, welding, or CNC machining — you’re likely battling:

  • Rising production costs from waste and multi-step processing
  • Longer lead times that slow your time to market
  • Design restrictions that prevent modern, complex features
  • Inconsistent tolerances leading to post-processing and assembly headaches

If you’ve hit a wall with part complexity or stamping cost reduction efforts, powder metallurgy may be the more efficient alternative.

What is a Powder Metal Conversion? (And Why It Matters)

Line

Powder metal conversion is an alternative to traditional manufacturing processes that redesigns parts with more cost-effective and optimized engineering. 
Rather than machining away material or casting molten metal, powder metallurgy compacts and sinters fine metal powders into high-precision components. This method enables:

  • Complex, intricate designs
  • < 5% material waste and greater efficiency
  • Stronger, more consistent parts with tight dimensional tolerances
  • Significant cost savings — especially for medium-to-high-volume production

 

In the right application, powder metal conversion can completely transform how your part is designed and manufactured — enhancing performance, extending service life, and significantly improving profitability.

Benefits of Powder Metal Conversions

Line

See how Atlas Pressed Metals helps companies like yours overcome manufacturing obstacles and improve outcomes:

  • Appliance manufacturer:
    Converted a washing machine lid cam to sinter-hardened powder metal — achieving a 66% cost reduction while doubling material strength to support a switch from metal to glass lids, all without requiring secondary machining or heat treatment.
  • Automotive supplier:
    Designed and produced a highly complex gear as a single, net-shape part with tight tolerances and faster turnaround. Run-out specification is 0.00267 inch (0.068 mm) max, while the part’s overall length had to be held within ±0.00196 inch (0.05 mm),
  • Tool manufacturer:
    Converted a complex part with intricate internal veins and external alignment features to sinter hardened powder metal — achieving precision, cost savings, and dimensional stability without secondary heat treatment​.

If you’re facing high costs, complex designs, or performance limitations with your metal parts — conversion might be the solution you’ve been searching for.

 

Download Our Whitepaper to Learn More →

Website Images 500 X 500 (3)

Can Powder Metallurgy Solve Your Manufacturing Problems?

Line

It depends on the situation. We begin with a manufacturing design consultation to get more information about your part. If your application is a match, PM conversion can replace costly machining and secondary treatments with a more efficient process. By compacting and sintering metal powders into near-net or net-shape parts, you gain immediate, measurable advantages:

  • Simpler design & assembly:
    Replace multi-piece assemblies with a single, strong powder metal part.
  • Lower cost per part:
    Eliminate machining, secondary heat treatments, and scrap losses.
  • Freedom to innovate:
    Produce complex geometries, high-precision internal structures, and fine features that are too expensive or impossible through traditional methods.
  • Consistent high-quality results:
    Ensure tight dimensional tolerances and repeatability across low-to-high-volume production runs.

If you’re unsure whether powder metallurgy is the right fit, our mechanical engineering consulting services can help. We’ll evaluate your part, application, and production goals through a collaborative manufacturing design consultation to determine if powder metal conversion offers cost and performance advantages.

1
Material Utilization & Cost-Effectiveness

98

 

Use raw materials efficiently, minimize scrap, skip machining operations, and increase throughput.




2
Design With Flexibility
97

 

Easily manufacture unique designs with enhanced durability, precise surface finishes, and fine edge details.

3
Guarantee Consistency & Quality

96

 

Maintain uniformity and precise tolerances across every part — delivering reliable quality at any scale.

Learn More About Powder Metallurgy Solutions

Line

Explore how to overcome metal parts manufacturing challenges:

Watch Powder Metal Conversion in Action:

Seeing is believing. Watch how Atlas Pressed Metals uses powder metallurgy technology to turn complex designs into high-precision, cost-effective components.


Company Workshops:


Webpage Background (4)

Need Help with a Powder Metal Solution?

Speak with an Atlas Expert Today!

Need a Solution?
Ask Us a Question

Contact Information

Mailing Address

125 Tom Mix Dr.
P.O. Box P
DuBois, PA 15801
USA

Testimonial

 

"Our Engineering team works directly with Atlas Pressed Metals to achieve our company goals. Atlas is always very helpful, gives us on-time delivery and the sales reps are always willing to research to get answers for our needs.”

- Amanda S., Associate Buyer | Healthcare Industry