Pillar Page

Case Studies

Real-world examples of how powder metallurgy delivered precision, cost savings, and supply chain reliability for customers in automotive, power tools, and industrial markets.

Power Tools

High-Torque Gearbox for Impact Wrenches

Customer: Leading Power Tool OEM

Challenge

Customer needed GB9 precision gears for a 1000 N.m impact wrench with 500+ hour service life and noise levels below 75 dB.

Solution

Designed planetary gear sets using KISSsoft shrinkage-compensated tooth profiles. Selected FC-0508 material with post-sinter sizing for maximum wear resistance.

Results

Achieved GB9 gear precision with noise below 70 dB
Passed 600-hour continuous load testing
Reduced per-part cost 22% versus machined gears at volume
Monthly supply: 500,000+ gear sets

Automotive

Diesel Engine Rocker Arms for Kia

Customer: Kia Motors / Tier-1 Supplier

Challenge

Required IATF 16949 certified rocker arms with consistent hardness, full traceability, and zero-defect delivery to Kia assembly lines.

Solution

Implemented SPC-controlled pressing density, automated sintering atmosphere monitoring, and 100% dimensional inspection on critical features.

Results

Kia SQ supplier qualification achieved
Zero PPM defects over a 24-month period
Annual volume: 2.5 million pieces
Full PPAP documentation and traceability

Garden Equipment

Low-Noise Gearbox for Pole Saws

Customer: Stihl-Approved Supplier

Challenge

Required compact, lightweight gearbox gears for a pole saw application with strict noise and vibration requirements.

Solution

Optimized tooth profile modification using KISSsoft to reduce meshing impact. Implemented double-action pressing for uniform density distribution.

Results

Noise level reduced to below 68 dB
Weight reduced 18% versus machined steel gears
500-hour life test passed with margin
Approved for mass production supply

Industrial Machinery

Machined to PM Conversion - Cost Savings

Customer: Industrial Pump Manufacturer

Challenge

Customer was machining gear pump rotors from solid steel, resulting in 60% material waste and high machining costs at 50,000 units per year.

Solution

Converted the design to a net-shape PM process. Optimized tooth profile for PM manufacturing and selected FC-0208 material with steam treatment for corrosion resistance.

Results

Material utilization improved from 40% to 95%
Cost reduction: 35% per part ($4.20 to $2.73)
Tooling payback period: 8 months
Annual savings: $73,500 at current volume

Medical Devices

316L Stainless Steel Surgical Components

Customer: Medical Equipment OEM

Challenge

Required complex 316L stainless steel components for a surgical stapler with tight tolerances and biocompatibility requirements.

Solution

Developed precision tooling for SS-316L-22 material. Implemented vacuum sintering for optimal corrosion resistance and passivated the final parts per ASTM A967.

Results

Achieved +/-0.02 mm tolerance on critical features
Passed 500+ hour salt spray testing
FDA biocompatibility compliance achieved
Cost 40% lower than CNC machining

Have a Similar Project?

Our engineering team can review your requirements and provide a tailored powder metallurgy solution with cost analysis and timeline.