High-Precision Powder Metal Transmission Gear
Client: Automotive Transmission Manufacturer — Michigan, USA — 2024
The Challenge
An automotive Tier 1 supplier needed a high-precision transmission gear produced at high volume with strict tolerances and consistent quality. Traditional machining was too slow and expensive for the required volumes.
Our Solution
We utilized our powder metallurgy process with a custom Fe-Cu-C alloy formulation. The PM process eliminated secondary machining operations and achieved near-net shape with excellent dimensional consistency.
Results
Production capacity of 100,000 parts per month achieved. Cost reduced by 45% compared to machined gears. Dimensional tolerance held to ISO 7 grade. Zero defects in PPAP validation.