SINTS compares metal injection molding, conventional powder metallurgy, gear manufacturing, CNC finishing and secondary operations from the same engineering brief. Geometry, material, annual volume, critical interfaces and final-part requirements determine the route before tooling is fixed.
MIM, PM and machining descriptions explain route considerations. They do not establish a tolerance, material or output commitment for every geometry.
See the factory pages for the equipment and site information in the current company materials. Applicability to a new program is reviewed with its drawing.
The agreed route must identify critical features, secondary operations, material condition, inspection and any exceptions before tooling release.
We do not force every job into one technology. The drawing, annual demand and functional risks decide which route should remain simple, which features can be consolidated, and where secondary control is worth paying for. For a broader comparison beyond the core SINTS routes, see 9 metal manufacturing processes.
Complex 3D geometry, thin walls, undercuts and side features where molded geometry and repeat production justify tooling.
Press-and-sinter production for gears, bushings, cams and structural components suited to uniaxial compaction.
PM, MIM and conventional gear-cutting or finishing routes are compared according to tooth geometry, load, accuracy, runout, heat treatment and annual volume.
Turning, milling, grinding and tapping for critical features that require secondary dimensional or surface control.
Heat-treatment routes are selected according to alloy, hardness, wear and customer specification.
Surface treatment, marking and assembly support are selected according to drawing and program requirements.
Browse the seven product categories by application, or send the drawing and let engineering compare the practical routes for you.
MIM uses fine metal powder mixed with a binder, injection molding, debinding and sintering to create compact three-dimensional metal components. Its value comes from geometry consolidation and repeat production—not from being a universal replacement for machining.
MIM is evaluated when the part has enough 3D complexity and repeat demand to justify tooling. The economic crossover depends on the drawing, material, secondary operations, validation scope and forecast volume, so SINTS does not publish one universal minimum or “best” annual quantity.
| MIM review item | How SINTS evaluates it |
|---|---|
| Geometry | 3D complexity, wall transitions, gates/parting lines, shrinkage and distortion risk are reviewed from the drawing. |
| Critical dimensions | As-sintered capability and any required machining/grinding are confirmed feature by feature. |
| Material | Documented grades and project-specific materials are checked against strength, corrosion, wear and finishing requirements. |
| Tooling / MOQ / timing | Quoted from part geometry, alloy, annual volume and validation requirements. |
SINTS supports press-and-sinter powder metallurgy for gears, bushings, cams and structural parts. Press direction, density distribution, tooling geometry, heat treatment and secondary finishing are reviewed from the drawing before PM is recommended.
PM is strongest when the part can be compacted along a practical pressing direction and the required density, tooth or bearing surfaces, heat treatment and post-sinter operations remain compatible with the functional requirement.
| PM review item | How SINTS evaluates it |
|---|---|
| Compaction geometry | Press direction, wall/step geometry and density distribution are checked before PM is recommended. |
| Functional surfaces | Bores, faces, teeth and datums are reviewed for sizing, machining, grinding or as-sintered control. |
| Material / density | Alloy, density/porosity and heat-treatment requirements are tied to the final application. |
| Tooling / MOQ / timing | Confirmed per drawing and forecast volume after the manufacturing route is selected. |
Tighter control can add tooling, secondary machining or inspection steps. The drawing should identify which dimensions are truly functional so SINTS can propose the most economical control route.
| Feature | Engineering review | Possible control route |
|---|---|---|
| Linear dimensions | Shrinkage, tool condition, datum scheme and tolerance stack are reviewed from the drawing. | As-sintered where practical; machining/grinding where required. |
| Bores & mating fits | Fit, concentricity and functional clearance determine the control plan. | Sizing, reaming, machining or grinding as needed. |
| Flatness / runout | Part geometry, support during sintering and mating function are evaluated together. | Process optimization plus secondary finishing when necessary. |
| Surface condition | Wear, sealing, cosmetic and coating requirements are confirmed per surface. | As-sintered, tumbling, polishing, machining, coating or other agreed finish. |
Drawing tolerances, datum schemes and geometric callouts are reviewed feature by feature. SINTS does not publish one universal tolerance or cost premium for every MIM/PM geometry.
Secondary operations are planned as part of the manufacturing route. Depending on the process and project, work may use SINTS in-house equipment or qualified supporting resources under the same project and quality requirements.
Heat-treatment options are selected according to alloy, drawing and required properties; the applicable route is confirmed during quotation.
Turning, milling, drilling, tapping and grinding on sintered blanks. Used where tolerance, thread quality or a sealing face demands it.
Tumbling, blasting, passivation, polishing and other finishing routes can be reviewed according to edge, surface and cosmetic requirements.
Plating and coating options are selected according to corrosion, wear, appearance and customer compliance requirements.
Part numbers, lot codes, logos and datamatrix directly on the component for traceability programs.
Riveting, pressing, staking, spring and pin insertion, threaded insert fitting, packaging to customer artwork.
Optical sorting, gauges and manual inspection can be applied to characteristics defined in the customer control plan.
Packing method is agreed according to part protection, shipment mode, destination and customer packaging requirements.
Engineers review geometry, wall sections, datums, material, functional features and process fit. Feedback timing is confirmed with the project quotation.
Tool design, steel cutting, T0 trial. Dimensional report on first shots before any production commitment.
First-article inspection and approval documentation are prepared according to the agreed validation plan; PPAP content is supplied when required by the customer program.
Production follows the agreed control plan, with critical-characteristic inspection, traceability and shipment documentation matched to the customer program.
Dedicated metal feedstock injection presses with closed-loop process monitoring and automatic part handling.
Vacuum and controlled-atmosphere sintering resources support PM and MIM programs, with thermal profiles and production records managed according to the applicable process plan.
Turning centres, 3-axis and 4-axis mills, centreless and surface grinders for post-sinter operations.
CMM, optical comparators, roughness testers, hardness testers, density apparatus and metallographic preparation.
Universal testing machine for tensile and yield verification per ISO 6892, plus impact and fatigue sampling.
Physical production references are maintained for engineering discussion. Similar geometry can inform DFM, but capability is confirmed from the new drawing.
Most capability pages describe machines in words. Here are the counts and the tonnages, because tonnage is the first hard limit on what press-and-sinter powder metallurgy can form in one piece. MIM injection capacity is listed in the second table, with route detail on the factory resource page and the MIM capability page.
| Press tonnage | Units | Projected area covered at 400–800 MPa |
|---|---|---|
| 5 t | 1 | 0.6–1.2 cm² |
| 6 t | 5 | 0.8–1.5 cm² |
| 25 t | 6 | 3–6 cm² |
| 50–65 t | 7 | 6–16 cm² |
| 100 t | 4 | 12–25 cm² |
| 140 t | 2 | 18–35 cm² |
| 160 t | 1 | 20–40 cm² |
| 200 t | 1 | 25–50 cm² |
| 218 t | 1 | 27–55 cm² |
| Total | 28 | — |
The area column is illustrative arithmetic, not a capability guarantee: ferrous powders compact at roughly 400–800 MPa, which is about 4–8 t/cm² of projected area. Actual pressure is set per material and part. Projected area is also not the same as part size — a long shaft pressed along its axis has a small footprint but still needs press daylight and fill height, and tooling, ejection and multi-level geometry constrain the answer as much as tonnage does.
| Process stage | Equipment | Units |
|---|---|---|
| MIM forming | Injection moulding machines (50–400 t) | 29 |
| Debinding | Debinding furnaces | 15 |
| Sintering — continuous | Continuous sintering furnaces | 4 |
| Sintering — vacuum | Vacuum sintering furnaces | 18 |
| Tray loading | Automatic tray-loading machines | 2 |
| Sizing / coining | Sizing presses | 24 |
| Grinding | Grinding machines | 14 |
| Cleaning | Cleaning line | 1 |
Two forming routes run in parallel: powder compaction on the presses above, and MIM injection on the 29 moulding machines. Sizing capacity matters more than it reads: it is the operation that recovers the ±0.1 mm features and fits that sintering cannot hold on its own. Vacuum sintering is used where atmosphere control decides the result — stainless grades, magnetic alloys and parts where carbon pickup has to be avoided.
| Instrument | What it establishes |
|---|---|
| Coordinate measuring machine (CMM) | Three-dimensional geometry, position and form of critical features |
| Optical comparator (2D) | Profile, edge and slot geometry on small parts |
| Contour and profile instrument | Form of arcs, chamfers and profiled sections |
| Surface roughness tester | Ra / Rz measured against the drawing |
| Universal testing machine | Tensile, yield and elongation |
| Hardness tester | Hardness in the scale the drawing specifies — HRB, HRC or HV |
| Density measuring apparatus | Sintered density against the density requirement |
| Metallographic analysis | Porosity and microstructure |
| Magnetic particle inspection | Surface and near-surface discontinuities on ferrous parts |
| Carbon / sulphur analyser | Carbon and sulphur content of powder and sintered material |
Ten instrument types in-house is what makes a first-article report mean something: density, hardness, chemistry, microstructure and geometry are measured here rather than subcontracted and reported second-hand. Counts are the plant equipment list at the time of publication and change as capacity is added — confirm current availability for a specific program.
MIM size suitability depends on geometry, wall sections, material, flow length, distortion risk and required properties. Send the drawing and SINTS will confirm whether MIM is practical or whether another route is better.
As-sintered tolerance depends on material, geometry, feature location, shrinkage and datum strategy. Critical dimensions are reviewed individually, with sizing, machining or grinding added where required.
MOQ is project-specific. Tooling economics, part geometry, material, annual demand and validation requirements are reviewed before a production MOQ is proposed.
Yes. SINTS can support heat treatment, CNC, grinding, tapping, tumbling, passivation, plating, PVD, laser marking and sub-assembly. The exact route and whether an operation is in-house or supported by a qualified resource are confirmed during quotation.
Tooling and first-article timing depend on geometry, mold complexity, material and validation scope. A project schedule is provided after DFM and drawing review.
Potential conversions are reviewed from the drawing, material, current process, annual demand and required performance. SINTS compares tooling and unit economics before recommending MIM, PM, CNC or a hybrid route.
