Fabrication

Formed as a single shape to a density of 6.8 to 6.9 g/cm³, the new PM design replaced a three-piece assembly. Critical design features include the locations of drafts, radii, and chamfers, as well as redefining tolerances for a near-net-shape part. Secondary operations include resin impregnation and zinc plating.
Extensive product design engineering was required to convert the three piece assembly into a single powder metallurgy friendly configuration.

Results

• The one-piece design provided a 21.5% cost savings over the previous assembly
• Conversion of a three-piece component into a single piece
• Machining scrap reduced