Table of Contents
Note: This page summarizes a representative application example. Results are specific to the described design, validation scope, and production conditions.
Executive Summary
Client: Commercial lock manufacturer Challenge: 3-part machined assembly expensive, assembly quality issues Solution: Single-piece PM lock cylinder body with complex internal features Results:
- 3 parts consolidated into 1
- 52% cost reduction
- Assembly time eliminated (15 seconds/lock saved)
- Tolerance improved: +/-0.03mm vs +/-0.08mm
Customer Background
Industry: Commercial security hardware Application: Medium-security door lock cylinder Volume: 250,000 locks/year Original Design: 3-part machined assembly (body + 2 inserts)
The Challenge
Problem 1: Assembly Complexity
- Issue: 3 parts required alignment + press-fitting
- Time: 15 seconds per lock
- Cost: $0.45/lock (labor + equipment)
- Quality: 3-5% rework rate (misalignment)
Problem 2: High Machining Cost
- Issue: CNC machining complex internal features (pin chambers)
- Cost: $3.20/part (material + machining)
- Waste: 65% material scrap (bar stock)
Problem 3: Tolerance Stack-Up
- Issue: 3-part assembly had +/-0.08mm cumulative tolerance
- Impact: Pin binding in 2-3% of locks
SinterWorks PM Solution
Material: FC-0808 (8% Copper Iron)
Why FC-0808?
- Adequate strength for lock body (no high stress)
- Excellent machinability (for keyway)
- Cost-effective
- Good dimensional stability
Manufacturing Process
- Precision Tooling: Multi-level compaction (8 internal pin chambers)
- Compaction: 600 MPa, green density 6.6 g/cm3
- Sintering: 1120 deg C, 25 minutes
- Sizing: Re-strike for +/-0.03mm tolerance on critical features
- Secondary Machining: Keyway broaching only (all other features net-shape)
Design Consolidation
Before (3 parts):
- Main body (machined)
- Pin chamber insert #1 (machined)
- Pin chamber insert #2 (machined)
After (1 PM part):
- Integrated lock body with 8 internal pin chambers
- Keyway broached after sintering
- No assembly required
Results
Cost Comparison (Per Lock)
| Element | 3-Part Machined | 1-Part PM | Savings |
|---|---|---|---|
| Material | $1.20 | $0.65 | 46% |
| Machining | $2.00 | $0.35 (keyway only) | 82% |
| Assembly Labor | $0.45 | $0 | 100% |
| Tooling Amortization | $0.08 | $0.45 | -462% |
| Total | $3.73 | $1.80 | 52% |
Annual Savings: $482,500 (250K locks)
Quality Improvements
- Tolerance: +/-0.03mm (vs +/-0.08mm)
- Rework Rate: 0.3% (vs 3-5%)
- Pin Binding: <0.1% (vs 2-3%)
Get Complex PM Lock Components
SinterWorks manufactures intricate lock components:
- Multi-level tooling for complex internal features
- Tight tolerances (+/-0.03mm)
- Secondary operations (broaching, threading)
- High-volume production (100K+ parts/year)
Related Resources
Use these internal links to keep moving through the most relevant guides, service pages, and technical references for this topic.
FC-0808 High-Copper PM
Review a cost-effective FC-series PM material used for structural hardware and repeat-volume mechanical components.
DFM Guide
See how multi-level tooling, feature consolidation, and tolerance priorities influence PM-friendly part design.
Fastener Components
Compare other precision hardware programs where PM can reduce machining and simplify repeat-volume supply.
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