MPIF Announces 12 Powder Metal Awards of Distinction

<p style="text-align: center;"><img src="/ueditor/php/upload/image/20250723/1753280583207111.png" title="1753280583207111.png" alt="7.png"/></p><p style="text-align: justify;"><span style="font-family: arial, helvetica, sans-serif; font-size: 12px;">The winners in the 2025 Powder Metallurgy (PM) Design Excellence Awards competition, sponsored by the Metal Powder Industries Federation (MPIF), demonstrate outstanding examples of PM’s diversity and ability to meet critical requirements. From electric vehicles to musical instruments to semiconductors, once again, parts fabricators have demonstrated PM’s versatility and unique ability to challenge competing technologies. These award-winning components use PM’s flexibility to push forward new concepts and process controls to demonstrate the inexhaustible range of PM’s capabilities. 12 Awards of Distinction were given to the following:&nbsp; In the Automotive—Engine Category for Conventional PM components, an Award of Distinction has been given to Nichols Portland Inc., NPI–Ridgway Division for a mounting boss for sensors used in automotive emission control systems. The bosses are made from stainless steels, chosen for their combined attributes of weldability and adequate corrosion resistance. The bosses are designed to be permanently welded in place, allowing quick assembly-line installation and long-term serviceability of a growing number of critical exhaust gas sensors. Machining these parts from wrought bar stock would result in a significant amount of wasted material compared with the PM process. In the Automotive—Transmission Category for Conventional PM components, an Award of Distinction has also been given to GKN Sinter Metals, for an oil pump assembly used in a new cost-effective dual-clutch transmission. This is the first time an electric motor has been fully integrated in a hybrid electric vehicle. The assembly comprises upper and lower covers, a gerotor set, a pump core and a copper steel bushing. The initial part design called for a die-cast aluminum part that required extensive machining. A redesigned PM part replaced the aluminum cover with significant advantages including improved pump performance, reduced NVH scattering, enhanced sustainability, and cost reduction. In the Automotive—Transmission Category for Conventional PM components, an Award of Distinction has been given to Burgess-Norton Mfg. Co. for a reaction block and cam plate used in a mechanical locking rear differential. This part is at the center of the assembly and sets the working distance between the four gears that are in constant contact with four sides of the part. The cam plate’s angled design allows it to wedge against the side gear, creating a locking action when the flyweight system detects a significant speed difference between the wheels. The three detent protrusions prevent the cam plate from ramping until a predetermined torque is applied to the gear teeth. An Award of Distinction has been given, in the Automotive—Chassis Category for Conventional PM components, to Metco Industries, Inc. for a damping piston in an automotive shock absorber system. The compaction process requires several independent press functions to compact the damping piston to both the correct dimensions and mass. Special handling applications, secondary machining, and a specialty lathe and fixture are utilized throughout the process. With multi-level high precision PM compacting press capabilities, the parts can be made to near-net-shape. Due to the complexity, it would not be economical to produce using alternative manufacturing methods. An Award of Distinction has also been given, in the Automotive—Chassis Category for Conventional PM components, to Phoenix Sintered Metals LLC and their customer ZF Chassis Solutions for an anti-rotational sleeve used in an electronic braking application. Maintaining part integrity through the compaction and ejection process is critical due to the thin cross-section where the flange joins the legs. The anti-rotation sleeve must meet tight tolerances. PM technology was chosen as the route that could pass all the testing requirements in an accelerated timeline.</span></p><p style="text-align: justify;"><span style="font-family: arial, helvetica, sans-serif; font-size: 12px;">In the Automotive—Chassis Category for MIM components, an Award of Distinction has been given to INDO-MIM LIMITED for an ASV top plate used in a vehicle suspension sub-assembly. The part is quite complex, featuring a circular shape with 30 narrow-through slots around the edge and five rib-like structures that connect to a central hole. MIM processing resulted in a 40% cost reduction compared with the machining and wire cutting previously used. MIM is an excellent choice for making 120,000 parts annually while minimizing material waste. In the Military/Firearms Category for MIM components, an Award of Distinction has been given to Advanced Powder Products, Inc. for a sear housing block used in a pistol firearm. There are numerous blind and through holes, all held to tight tolerances for position and depth, and thin walls that form functional features where subsurface defects are not acceptable. X-ray scanning was used to verify that the parts were free of subsurface defects. CNC machining of the part was not cost effective for the desired volumes or the requested speed to market. In the Lawn &amp; Garden/Off-Highway Category for Conventional PM components, an Award of Distinction has been given to MPP for a clutch shoe used in a centrifugal clutch used in a chain saw assembly. The offset features on the flange present compaction difficulties; potential for cracks, issues with density distribution, and tool life. These were overcome using an innovative compaction tool set that included two upper punches, four lower punches, two core pins, and a compensated fill die with a powder sweep. PM was selected because the complexity of the required geometry makes other manufacturing methods unfeasible and uneconomic, especially at the higher annual volumes needed. In the Hand Tools/Recreation Category for Metal AM components, an Award of Distinction has been given to Nichols Portland Inc., NPI–MIM/MAM Division for a bar and yoke banjo capo assembly for Paige Musical Products. A capo is used to temporarily shorten the strings on a banjo, raising the pitch of the unfretted or “open” strings and changing the key of the open-position chords. The two parts are made from stainless steel and used in the as-printed-and-sintered condition with no secondary processing. The metal AM parts provide a 50 percent cost reduction compared with traditionally machined components. In the Medical/Dental Category for MIM components, an Award of Distinction has been given to Hangzhou Sino-MIM Technology Co. Ltd. for an anvil of an endoscopic stapler used for tissue re-section and anastomosis in thoracic and abdominal surgical operations. The stapler uses titanium staples to cut off or anastomose tissues. It is quick and easy to operate and greatly shortens the operation time. The parts are made from stainless steel and are nickel-Teflon plated to meet biocompatibility requirements. Redesigning the machined parts that required extensive processing to MIM resulted in a 50 percent cost reduction. An Award of Distinction, in the Electronic/Electrical Components Category for MIM components, has been given to Hangzhou Sino-MIM Technology Co. Ltd. for an ALN heatsink. This part is made from aluminum nitride and is very brittle. The part is used in the silicon photonics optical module for optical communication. A large number of heat-generating components are surface-mounted on the product, which not only serves as the mounting substrate but also plays a role in heat conduction and dissipation. Surface finish and tight tolerances on the flatness and parallelism are among the part requirements. An Award of Distinction, in the Electronic/Electrical Components Category for MIM components, has been given to Hangzhou Sino-MIM Technology Co. Ltd. for a MIM-17-4 PH stainless steel middle plate used in the hinge of the folding screen of a mobile phone. The middle plate connects multiple mechanical devices and serves as the core part of the mechanical rotating part of the folding screen. The parts are processed by high precision equipment to ensure the dimensional accuracy. The thinnest part is only 0.3 mm (0.012 inch) thick.</span></p>