Miniature Precision Components

The fabrication of miniature precision components with intricate features and micron-level tolerances not only requires specialized manufacturing techniques, but a high level of competence in using them. Tiny metal gears, sprockets, cams, and other small parts are used in everything from advanced medical devices to high-voltage circuit breakers. In addition to requiring less material and energy to produce, these tiny metal parts help support trends toward smaller, lighter devices and machinery.

Using powder metallurgy, Allied Sinterings, Inc. produces tight-tolerance, small-profile custom metal components and assemblies used in sensitive applications across the medical, automotive, telecommunications, and industrial equipment sectors. These parts are manufactured to exact technical specifications and high quality standards to facilitate safe and dependable performance by the critical devices and equipment they support.

Small Metals Parts Fabrication

Powder metallurgy has become an attractive solution for creating small, highly intricate parts that would be difficult or impossible to achieve through other metal-forming methods. The shapes and geometric features that can be produced using this metal-forming process are nearly unlimited.

Some advantages of powder metallurgy for small part production include:

  • Tight tolerances. The powder metallurgy process can produce parts with extraordinarily complex designs within extremely tight tolerances. Producing accurate parts during initial production reduces or eliminates the need to refine tolerances through secondary machining.
  • Net-shape process. As a net- or near-net shape process technology, powder metallurgy allows small components to be directly formed into their final size and shape. This means the component can be market-ready after just a single process, eliminating or reducing the need for machining and other secondary operations.
  • Good surface finish. The powder metallurgy process delivers uniform surfaces that can be further enhanced or customized through finishing treatments. A good surface finish improves a part’s durability, performance, and wearability within its application.
  • Long-term performance reliability. By tightly controlling dimensional tolerances and physical properties, powder metallurgy produces parts that exhibit consistent performance and long-term reliability in their intended applications.
  • Material diversity. Powder metallurgy is compatible with an impressive range of materials, including stainless steels, iron, copper, and nickel-based alloys. Powder metallurgy also allows materials to be combined in ways that would otherwise be impossible.
  • Low manufacturing costs. Because it produces near-net shape parts, powder metallurgy allows for relatively short processing times and eliminates the need for expensive and time-consuming finishing operations. This leads to improved turnaround times and reduced labor and production costs, even for complicated parts and moderate-to-high production volumes. The ability of powder metallurgy to mass produce precision parts in a cost-effective way makes it an attractive production method.
  • Low tooling investment. When compared with conventional metal forming methods, the powder metallurgy process is generally associated with a much lower tooling investment. The overall tooling cost will depend on the size and complexity of the part.

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Industries & Applications

Miniature components produced through powder metallurgy support applications in a wide range of industries, including:

  • Medical. Miniature parts and micro-components are extremely vital to the operation of medical devices and precision surgical tools. High-precision metal forming processes are essential for producing everything from custom miniature gears to respirator parts and medical device components.
  • Automotive. Automotive systems require the aid of small, durable components to operate smoothly, reliably, and efficiently. Miniature metal part manufacturing is used in the automotive industry to create fine-pitch gears, rotors, pinions, brake parts, gaskets, and other essential components.
  • Telecommunications. The telecommunications industry is a dynamic technological field requiring high-quality small components to support devices and equipment that help make large-scale communication and information sharing possible. Examples of these components include couplers, adapters, fiber optic parts, and more.
  • Industrial. The operation of power tools, lifts, and other industrial equipment is supported by a wide variety of miniature accessories and components. Small, high-precision gears, pins, and other intricately shaped parts allow these types of devices to run safely and efficiently. 
  • Robotics. The recent trend toward smaller robotic designs has further increased the need for miniature components with high levels of precision. Tiny custom-molded washers, bearings, and other specialty metal parts have been created to solve a variety of unique robotics design challenges.
  • Consumer goods. The diverse and dynamic consumer goods industry includes a wide range of products, from electronic gadgets and exercise equipment to household appliances and toys. Small, high-precision gears, electronics parts, and other specialty components have helped facilitate product designs that are more compact and energy-efficient.

Types of Metal Parts

At Allied Sinterings, our metal forming expertise, comprehensive in-house tooling capabilities, and expert finishing services allow us to create high-precision miniature components for a wide range of applications. Our typical products include:

Gears and pinions

Gears and pinions
Our miniature gears and pinions are designed with exceptional accuracy and attention to detail, allowing them to fit perfectly into high-precision devices and instruments. We also produce compact metal gearboxes that support critical applications in the medical field and other industries.

Assemblies and sub-assemblies

Assemblies and sub-assemblies
We specialize in producing small, custom-engineered metal assemblies and sub-assemblies designed for a range of applications, including medical devices, industrial equipment, and various electrical appliances.

Sprockets

Sprockets
Our high-precision miniature sprockets are produced with exceptional accuracy to enable smooth, controlled rotations within small rotary motion applications.

Cams

Cams
Our miniature cams can be constructed from a variety of materials and custom-designed to support specific applications.

Retainers

Retainers
Our precision-molded metal retainers are engineered to keep components firmly in place within their assemblies.

Custom Miniature Components from Allied Sinterings, Inc.

With the need for component miniaturization across numerous industries, the demand for small, high-precision components is higher than ever. These tiny metal components and assemblies are essential for improving existing products as well as enabling the development of new ones. Advances in powder metallurgy have made it one of the most cost-effective manufacturing methods for the high-volume production of miniature components in demanding and competitive industries, including automotive, aerospace, medical, robotics, and more.

 

Allied Sinterings specializes in the production of high-quality small parts that are expertly crafted for durable, long-lasting performance in a range of applications. Our efficient powder metallurgy manufacturing process and in-house design department allow for short lead times and on-time deliveries, no matter how much customization or detail is involved. We also utilize computer-supported statistical process control and advanced monitoring technologies to ensure the production of high-integrity, defect-free products with tolerances within ±0.001 inches. In addition to being extremely efficient and accurate, our sintering process is a recognized “green” technology with low relative energy consumption and a 99% material utilization rate.

 

To learn more about our miniature powdered-metal parts and how we can help you with your next project, please contact us today.