Powdered Metallurgy
Process Description Fine metal powder is fed through an automated hopper into a vertically activated die. Hydraulic presses compact powder into the component's shape. The "Green" component is then heated in a controlled atmosphere sintering furnace to fuse the particles into a solid shape. Advantages Low cost tooling and unit price High capacity, tight tolerances, Intricate shapes without machining Self-lubricating Zero draft capabilities Manufacturer Brownco Powdered Metal	Market Niche Volume Low to high (500 to 1,000,000) Materials Steel, iron, stainless, brass, aluminum, bronze, & copper Applications Gears, impellers, nuts, spacers, bearings, rollers Finishing Option(s) Resin impregnation, oil impregnation, plating and painting Secondary Operations Drilling, tapping and machining

Metal Injection Molding
Process Description A custom formulated mixture of Metal Powder and binder is injected into a mold. After removal of the green part from the mold, the binder is removed and the part is sintered (solid state diffused) in a controlled atmosphere furnace. The process is very similar to plastic injection molding and high pressure die casting since it can provide much the same shapes and configuration features. Advantages Provides mechanical properties nearly equivalent to wrought materials A net shape process technology with good dimensional tolerance control Nearly unlimited shape and geometric feature capability High production rates through use of multi-cavity tooling		Market Niche Volume Low to medium (200-30,000) Materials Full range of carbon steels and stainless steels Applications Computer peripherals, medical and dental devices, automotive, firearms, electronic packaging, consumer products, air bag sensor parts. Finishing Option(s) Painting and plating Secondary Operations Drilling and tapping

Machining
Process Description Part shape is obtained by removing material through turning for round shapes, or milling for flat shapes. Turning is performed on horizontal lathes or screw machines. Milling is performed on vertical machining centers. Advantages Excellent dimensional control and design flexibility Low cost tooling and fixtures No draft angle requirements Manufacturer: General Plug & Mfg Company		Market Niche Volume Low to high (1 to 1,000,000+) Materials Aluminum, brass, copper, stainless steel and steel Applications Anywhere tight tolerances are needed. Undercuts, grooves, & thin wall sections, are good candidates for machining from scratch, or from a near net shape "blank" Finishing Option(s) Heat treat, plating, polishing, & painting Secondary Operations Tumbling, de-burring, & tapping

Zinc Die Casting
Process Description Molten Zamak (Zinc aluminum alloy) is injected under high pressure into a conventional, or multi-slide die. Parts are removed from the runner/gate via tumble, punch press or machining. Advantages Longer die life than aluminum Multi-slide: Faster cycle times than conventional dies Less expensive tooling due to reduced number of cavities required Manufacturer Carteret Die Casting		Market Niche Volume Medium to high (10,000 to 1,000,000) Materials Zamak 3,5,8 Applications Weights: Miniature up to 4 pounds. Fiber optic connectors, electronics, heat sinks, thin wall sections down to .007" Conventional Extremely tight tolerances Excellent cosmetic appearance, smooth surface finishes Finishing Option Painting, powder coating, plating, polishing, and assemblies Secondary Operations Drilling, tapping, and machining

Aluminum Die Casting
Process Description Molten aluminum is injected under high pressure into a closed single or multiple cavity automated die. Parts are removed from the runner/gate via tumble, punch press, or machining. Advantages Pressure tight castings with no porosity High strength to weight ratio Complete CNC machining for precision applications		Market Niche Volume Medium to high (10,000 to 1,000,000) Materials 360 to 380 aluminum alloys Applications Engines, clutches, valves, computer and medical Finishing Options Painting, powder coating, polishing, and plating

Stampings
Process Description Flat metal (coil or strip) is fed into a press that forms the desired part shape through a series of dies. Stampings fall within 4 basic categories: Compound Die Simplest of all stampings. Part is formed in a single station die in one stroke of the stamping press. Good for flat parts up to 1 inch thick. Manufacturer: Cly-Del Progressive Die Part is formed by using a series of dies and press strokes to form desired shape. Complex shapes and bends are possible as long as draw depth is limited. Manufacturer: Cly-Del Deep Draws Similar to progressive die but process focuses on forming tubular shapes with draw depths to 6 inches. Manufacturer: Cly-Del		Advantages Stamping process and tooling can be changed as part volume increases to lower unit cost Market Niche Volume Low to high (100 to 1 million) Materials Aluminum, brass, copper, stainless steel, and steel Applications Brackets, electrical contacts, covers, and housings Finishing Options Tumbling, plating & painting Secondary Operations Tapping, assembly, flattening, and coining

Cold Heading/Forging
Process Description Coiled wire is straightened as it is fed into high speed, horizontal, forming machines. Wire is then formed into part's shape through a series of dies and upsets. Various diameters and shoulders can be formed utilizing this process. Threads (if applicable) are formed using high-speed thread rolling machines that squeezes the unthreaded "blank" between two dies. The blank is stretched during this process displacing material to form a thread that is larger in diameter than the "blank." Advantages Virtually zero scrap and lower cost material than bar stock Excellent strength due to material grain flow during heading process High capacity with good dimensional control and surface finish Manufacturer General Plug & Mfg. Company		Market Niche Volume High (25,000+) Materials Aluminum, brass, copper, stainless steel and steel Applications Screws, pins, rivets, & rollers Finishing Option(s) Heat treating, plating & polishing Secondary Operations Threading, drilling, tapping & machining