Fabrication

Molded to a density of 6.7 g/cm³, the part has an ultimate tensile strength of 60,000 psi, minimum yield strength of 50,000 psi, 125,000 psi transverse rupture strength, and 23,000 psi fatigue limit. The complex net-shape design features 112 gear teeth and 16 assembly holes.
The component is molded near-net shape, except for the tapping/threading of 14 assembly holes, turned relief under the gear teeth, and trimming of the ID and bevel.

Results

• 60% cost savings over the previous machining method of making the part.
• Designing with powder metallurgy reduced the assembly part count from 24 to 6 parts.
• Selecting PM also cut lead times and allowed for easier assembly and disassembly in the field.