Frequently Asked Questions

GKN Powder Metallurgy specializes in several advanced technologies: Conventional Powder Metallurgy (PM), Metal Injection Molding (MIM), Forged Powder Metallurgy, two types of Additive Manufacturing (Laser Powder Bed Fusion and Binder Jetting), metal powder production, permanent magnet production, and porous metal technology. Our expertise allows us to deliver precision components and innovative solutions that drive performance, efficiency, and sustainability across industries.

Yes! GKNPM offers end-to-end prototyping and product development services, including:

• Rapid prototyping using Additive Manufacturing (AM) or MIM for early-stage testing
• Custom material development to match application-specific requirements
• Engineering support for design validation and performance optimization
• Simulation & testing to analyze durability, thermal properties, and mechanical strength

Our innovation centers in Germany and the USA specialize in cutting-edge R&D, helping customers bring ideas to reality.

Sintered metal components offer several key advantages over traditional machining, casting, or forging:

• Cost-Efficiency – Minimal material waste and lower production costs
• Design Flexibility – Complex shapes and near-net-shape production without extensive machining
• High Performance – Consistent material properties and enhanced wear resistance
• Lightweighting – Engineered porosity and material selection for weight reduction
• Sustainability – Efficient use of metal powders, reducing waste and energy consumption

By using Powder Metallurgy, manufacturers can achieve high-strength, precision-engineered parts with lower environmental impact and reduced costs.

We collaborate closely with customers at every stage of the product lifecycle, offering:

• Expert material selection – optimizing alloys and powders for performance
• Design-for-manufacturing (DFM) guidance – ensuring cost-effective, scalable production
• Advanced simulation & testing – validating mechanical properties and durability
• Customized solutions – tailoring products to unique application requirements
• Technical training & workshops – sharing knowledge on PM, AM, and MIM technologies

Our global engineering teams help customers push the boundaries of innovation, efficiency, and sustainability.

Each manufacturing technology has specific design considerations to ensure optimal performance, manufacturability, and cost efficiency.

Powder Metallurgy (PM) Design Guidelines:

• Best suited for high-volume production of precision components
• Design for uniform wall thickness to prevent density variations
• Avoid sharp corners and sudden thickness changes to improve compaction
• Incorporate draft angles for easier ejection in pressing processes
• Use self-lubricating properties of sintered parts for friction-reducing applications

Forged Powder Metallurgy (FPM) Design Guidelines:

• Ideal for high-strength, high-fatigue applications requiring increased density
• Start with near-net-shape PM parts, then forge for enhanced mechanical properties
• Maintain uniform material flow to reduce stress concentrations
• Design for precision post-forging machining where needed
• Consider heat treatment compatibility for additional strength and durability

Additive Manufacturing (AM) Design Guidelines:

• Supports complex geometries, lightweight structures, and lattice designs
• Avoid solid, bulky parts—optimize for internal channels and material efficiency
• Utilize topology optimization to enhance strength while minimizing weight
• Consider post-processing needs such as machining, heat treatment, or surface finishing
• Ensure support structures are included where necessary for overhangs and intricate features

Metal Injection Molding (MIM) Design Guidelines:

• Best for small, intricate parts with tight tolerances
• Maintain consistent wall thickness to prevent shrinkage variation
• Avoid sharp edges and undercuts that complicate the molding process
• Incorporate radii and fillets to improve material flow and strength
• Design parts for binder removal and sintering shrinkage compensation

Need expert guidance? GKNPM’s engineering team works closely with customers to optimize designs for manufacturability, strength, and performance, ensuring the best technology is chosen for your application.

We maintain high-quality standards across all our manufacturing technologies. Our quality assurance measures include:

• Advanced material testing – strict control of metal powders, alloys, and process parameters
• In-line and final inspections – real-time monitoring and quality checks throughout pressing, sintering, forging, printing, and filtering
• ISO-certified facilities – meeting global standards like IATF 16949, ISO 9001, ISO 14001, and AS9100
• Simulation & validation – using digital twin technology and advanced simulation tools to predict performance
• Process control & traceability – tracking each step of production for consistency and repeatability
• Post-processing & finishing – precision machining, heat treatment, and surface finishing for AM, FPM, and sintered parts