Manufacturers in a wide range of industries are showing greater interest in using powder metal manufacturing to replace some of the components made in more traditional ways. Powder metal can deliver a cost savings of up to 70% over other manufacturing processes, but there are more benefits to powder metallurgy than simply saving money. See how powdered metal manufacturing can benefit your business below:
Top Powdered Metal Manufacturing Benefits by Industry
Future Trends: Electrification of the Automobile
Powder metal manufacturing has many different uses in the automotive industry. The usage in a car can range from structural applications to magnetic applications. Current usage in a car is 40-80 lbs. (Certain SUVs lean toward the higher end, especially those with 4-wheel drive.)
Since powder metal can be molded, it allows auto manufacturers to create custom stators. While powder iron stators are not yet cost-competitive with laminated steel, the potential* is there for cheaper and more efficient motors.
(“Potential” is a huge word in powder metal manufacturing. In many cases, designs are limited only by your imagination!)
Using powder metal in the engine mounting system can deliver a sportier feel to the ride, while promoting stability and comfort. Powering the improved driver experience is a unique magnetic field that is both fluid and electrically generated. The magnetic field can change fluid viscosity immediately, softening the engine mount for a softer, smoother ride.
Car manufacturers can also use powder metal for rotors and electrical coils. Powder metal shines when low core losses are a must. It also does well at high frequencies, since magnetic frequency positively affects performance. What this means for transportation manufacturers is better:
- Running costs
- Environmental benefits
- Power ratings
End customers can save money on electricity, as the typical savings of switching to SMC powder metal average 5-20% percent. The short-term price increase of switching materials is offset by being able to promote the energy savings and environmental benefits -- a powerful brand differentiator in the market.
Food & Drink
Food and beverage applications require clean, maintenance-free materials that promote a sterile food handling environment. Powder metal manufacturing has several uses within food processing equipment, such as:
- Meat grinder plates
- Hardware knobs for ice cream machines
- Oven handles
Using powder metal helps the component resist corrosion and last far longer than plastic or die-cast pieces.
Powder metal easily produces grooves, tapers, irregular curves, and other net shapes for custom needs. High repetitive accuracy makes it easy to reproduce parts, saving time and money when equipment components break down.
Electronics
Electronics is a highly competitive industry, where manufacturers and customers both value innovation in design.
Powder metal manufacturing delivers cost savings in production along with world-class sound. Powder metal can be used within the loudspeaker core or other speaker parts. Unlike other materials, powder metal shines at frequencies above 200 Hz, which can increase the speaker sensitivity without overloading the amplifier.
Where Will Switching Help You Hit Goals?
These examples illustrate a few of the most important benefits for manufacturers and end-consumers in industries that commonly use powder metal parts. As a manufacturer, it is vital that you understand how switching to powder metal not only improves your product and costs, but how it affects the consumers experience (and also the cases where powder metal isn’t the right fit).
When you can translate these benefits for your customers, you increase your market differential and create demand.
