CASE STUDIES AND PM PART EXAMPLES
CASE STUDIES
SST’s presses and other technology produce powder metal parts with a high degree of complexity and configuration. Thanks to our multi-level compacting presses, we can achieve net or near-net shapes, reducing otherwise costly machining operations.
LAWN
& GARDEN
This customer came to us with an open-ended application. The need was to connect a linear actuating arm to a rotating shaft with a D-flat. Additionally, the component had to live through life cycle testing under moderate to heavy loads. After several sessions of online collaborations, a design was reached that solid modeling and geometric element analysis indicated would meet the established criteria. Sterling Sintered created prototype components for functional testing. We selected materials and produced a successful product.
POWER
TOOLS
This customer came to us with a machined brass part, looking to reduce costs. Converting to a powder metal part was the objective. After several sessions of simultaneous engineering, we eliminated the six machining operations and completed the part in one compaction.
LOCK
HARDWARE
This customer came to us with two stampings, two cold-headed pins, and a powder metal component for us to quote. When we finished the early design involvement, those five components became a single complex powder metal part. This component arrives at their facility with no sub-assembly required. What’s more, this part had to be able to live through an application of high-torque impact. The customers’ test involved a three-foot black iron pipe and a 16-pound sledgehammer. With the materials available in powder metal today, the part exceeded the sledgehammer impact test. Like every part we make, we perform strength tests as we manufacture them. This part has been passing the test since the inception of this part.
PLUMBING
This plumbing industry customer came to us with a problem to solve that would be relatively expensive to make through traditional machining. With some creativity, we accomplished it with a powder metal part with only one machining operation. This combination of internal splines and counter-bores with the external configuration and the pie-shaped element on the top make this part best produced in a technology that minimizes machining operations. That’s PM. This part is a good demonstration of what happens when can-do attitudes meet superior equipment. This customer brought us a part that was near impossible to make, and through simultaneous engineering efforts, we solved his design problem.
APPLIANCES
This customer came to us with a sub-assembly to reduce costs by eliminating components and assembly operations. The challenge included one injection-molded part, two commercial fasteners, and a threaded brass insert. After several sessions of concurrent engineering, we eliminated three components as well as the assembly operations. All features presented by the additional components could be designed integral to the powder metal part.
POWDER METAL PART EXAMPLES
6: MULTI-LEVEL & COMPLEX
This part has a very deep, oddly shaped counter-bore on the side you can see, multiple steps on the outside, and an arm with a cylindrical protrusion. All these attributes combined into one part make it an extremely challenging PM part for any PM manufacturer.
5: COMPLEX 2
This combination of internal splines and counter-bores with the external configuration and the pie-shaped element on the top make this part best produced in a technology that minimizes machining operations. That’s PM. This part is a good demonstration of what happens when can-do attitudes meet superior equipment. This customer brought us a part that was impossible to make, and through simultaneous engineering efforts, we solved his design problem.
4: COMPLEX
This part has a deep counterbore on the other side you can’t see. That, combined with the internal configuration and the multiple steps on the face you can see, make this part one you don’t want to give a novice.
3: THREE-LEVEL
What makes this part unique, beyond being three levels on the side you can see and two on the other, is the tight tolerances and the need to live through an application of high-torque impact. The customers’ test involved a three-foot black iron pipe and a 16-pound sledgehammer.
2: TWO-LEVEL
This simple-looking part is a good application for PM and an example of why PM is considered a “green technology”: the part is two levels with no machining required. Most other processes for making this part would have thrown away a lot of chips. No chips were harmed in the manufacture of this part.
1: SINGLE LEVEL
This is a piece of cake!
GET CUSTOM MADE POWDER METAL PARTS ON TIME, ON BUDGET
Sterling Sintered processes hundreds of different powder metal parts daily, each with its unique process flow and operational requirements. These operations are coordinated by a state-of-the-art computerized manufacturing management system, while our shipping schedule seamlessly pulls parts from upstream operations.
Call our office directly at (860) 379-2753 or contact us today to learn more.