Aerospace / Military Case Studies

From filters on medical and emergency breathing systems to firearms to aerospace engines, powder metallurgy (PM) has been intricate to the defense and aerospace industries for decades. When it comes to safety, powder metallurgy meets or exceeds customer requirements. If your company is looking for reliability, high-quality, consistency, and efficiency, then PM might be right for you.

The aerospace and military case studies below are a small sampling of award-winning parts submitted to the Metal Powder Industries Federation's annual Powder Metallurgy Design Excellence Awards competition.


Casing Extractor

This component is a casing extractor for pistols. It was endurance tested by civilian and military units, firing over 15,000 rounds.  

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Enclosed Striker

The enclosed striker is integral to the firing mechanism of a commercial grade pistol.


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This stainless steel powder metallurgy (PM) component is used on the Talon, an add-on guidance and control package that transforms a legacy 70-mm

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Front Sight Base

The size of this component, which is much larger than the typical metal injection molded (MIM) part, as well as the complex geometry, presented a challenge for the MIM process.

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Frame Chassis

This component is a frame chassis used in a


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Internal Latch

This component, made from a low-alloy steel, is an internal latch that drives a subassembly for the telescoping feature of the collapsible stock on MCX and MPX rifles.

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Rear Sight

Complex part geometry drove the need for an elaborate tool design with tight tolerances making metal injection molding (MIM) the most costed effective and high-quality method of production.

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A compact, lightweight, hand-emplaced munition device with extensive design and qualification requirements including cost efficiency and control.

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Bolt Handle

This component is a bolt handle for a hunting rifle.


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This ferrule is used in aerospace engines to provide a conductive path between the screen and engine. It also provides

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U-Bracket and Stop

The two metal injection molded parts shown are a U-bracket and stop, and are used in a Feedbox Support Improvement Kit (FSIK) for an M249 squad automatic weapon (SAW) used by the U.S. Military.

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