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Should I use powdered metal or die casting?
The first split is alloy: powdered metal makes iron, steel and stainless parts, while die casting is limited to aluminum and zinc. Choose PM for small, wear-loaded parts such as gears, cams and bushings that need steel hardness. Choose die casting for larger, thin-walled housings, covers and brackets with ribs, bosses and side features that PM cannot press.
Which is cheaper at your quantity?
The same housing, each process in a suitable material (17-4 PH and A380).
| Quantity | Powdered metal | Die casting |
|---|---|---|
| 10 | $1,397 | $2,257 |
| 50 | $281 | $451 |
| 100 | $146 | $227 |
| 500 | $37.00 | $47.20 |
| 1,000 | $23.40 | $24.80 |
| 5,000 | $12.60 | $6.81 |
| 10,000 | $11.20 | $4.57 |
| 50,000 | $10.10 | $2.35 |
| 100,000 | $9.99 | $1.98 |
Where each pays off
Powdered metal
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- Tooling
- 6–12 weeks
- First article
- 2–3 weeks after tooling
- Production
- 4–8 weeks per release
About ±0.001 in per in (±0.1%) as sintered; about ±0.0005 in (±0.013 mm) after sizing
Zinc and aluminum die casting
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- Tooling
- 8–14 weeks
- First article
- 1–3 weeks after die tryout
- Production
- 3–6 weeks per release
±0.002–0.010 in (±0.05–0.25 mm) on the first inch, plus about ±0.001 in per added inch (NADCA precision to standard)
Which should you pick?
Pick Powdered metal when
- The part needs steel strength or heat-treated wear resistance
- It is a gear, sprocket or cam
- It is an oil-impregnated bearing
- It weighs under about 2 lb (0.9 kg) with features along one axis
Pick Die casting when
- The part is a thin-walled housing with ribs and bosses
- It is larger than about 6 in (150 mm) across
- Light weight in aluminum matters
- Side features need slides and cores
Key differences
| Powdered metal | Die casting | |
|---|---|---|
| Alloys | Iron-copper and nickel steels, 316L; 17-4 PH by MIM | Aluminum A380 and A383; zinc Zamak 3, Zamak 5 and ZA-8 |
| Part size | Up to about 6 in (150 mm); most under 2 lb (0.9 kg) | About 0.1–25 lb (0.05–11 kg) |
| Geometry | Pressing-axis features only; no side undercuts | Thin walls, ribs, cored holes and slides |
| Minimum wall | 0.060 in (1.5 mm) | Zinc 0.020–0.040 in (0.5–1.0 mm); aluminum 0.040–0.080 in (1.0–2.0 mm) |
| Heat treatment | Quench and temper to HRC 20–43 apparent | Generally not; porosity blisters |
| Tooling cost | $5,000–$50,000 | $10,000–$100,000+ |
| Porosity | Designed in; can hold oil for self-lubrication | Gas porosity; impregnate for pressure tightness |
Questions
Which is cheaper, powdered metal or die casting?
For small steel parts such as gears and cams, PM usually wins, since die casting cannot make steel. For larger nonferrous housings, die casting wins, since PM is limited to parts of about 6 in (150 mm) with simple pressing-axis shapes.
Can zinc die cast gears replace powdered metal gears?
For light-duty gears, yes. Zamak 5 holds tooth form as cast and wears better than Zamak 3. For higher loads, powder metal FC-0208 or FN-0205 is the better call.
What about metal injection molding?
MIM molds fine metal powder with a binder, then sinters it to about 97% density. It suits small, complex steel and stainless parts under about 100 g that neither pressing nor die casting can shape.
Try both on your part.
The builder prices the same geometry in every suitable process and material, with DFM for each.