Producing precision metal components with complex geometries, high repeatability and improved material efficiency is an increasingly relevant challenge in demanding industrial projects. Sintering, a technology within the field of powder metallurgy, responds to this challenge by enabling the production of dimensionally stable, functional and competitive technical parts for series production.
The recent availability of the sintering process represents another step in strengthening ETMA’s production capabilities, making it possible to develop precision metal components with greater efficiency, dimensional accuracy, improved material utilisation and the possibility of working with different steel alloys.
More than a new production capability, sintering represents a technical solution aimed at projects where the geometry, material, cost and final performance of the part must be carefully balanced.
WHAT IS SINTERING?
Sintering is a thermal process applied to parts that have previously been compacted from metal powders.
In the first stage, the metal powder is placed in a tool and pressed under high pressure, forming what is known as a green compact. At this stage, the part already has a geometry close to its final shape, but does not yet have its definitive mechanical properties.
The component is then subjected to a controlled thermal cycle, usually in a furnace with a protective atmosphere. During this process, the metal particles bond together through diffusion, increasing the density of the parts and, consequently, also improving the strength, dimensional stability and functionality of the component.
The result is a technical metal component, produced with high repeatability and with less need for material removal compared to conventional machining processes.
WHEN DOES SINTERING ADD VALUE?
Sintering is particularly relevant when it is necessary to produce parts with complex geometries, in medium or large production runs, with dimensional accuracy and cost control.
By starting from compacted metal powders, the process makes it possible to obtain shapes close to the final geometry of the part, reducing raw material waste and limiting additional machining operations. This characteristic makes sintering especially interesting for small and medium-sized components, where precision and repeatability are decisive.
Another important advantage is the possibility of working with different steel alloys, adjusting the material and the process to the requirements of the final application. Depending on the project, complementary operations may also be carried out, such as sizing, heat treatments, surface treatments or final inspection.
In this way, sintering makes it possible to combine several requirements in a single solution: complex geometries, dimensional precision, waste reduction, lower transformation cost and consistency in series production.
FROM COMPACTION TO THE FINAL PART: A CONTROLLED PROCESS
The quality of a sintered part depends on rigorous control of the different stages.
Everything begins with the selection of the metal powder, which directly influences the density, mechanical properties, dimensional behaviour and final performance of the component. The geometry of the part must then be adapted to the compaction / sintering process, in order to ensure that the tooling has the reliability required to support long production runs.
Process control is also decisive. The stages of tool filling, compaction and the sintering cycle must be rigorously monitored, as temperature, time and atmosphere have a direct impact on the properties of the part.
After sintering, additional operations may be required to meet specific tolerance, finishing, strength or surface protection requirements. Sizing, for example, makes it possible to improve dimensional accuracy. Heat treatments and technical coatings, on the other hand, can enhance the performance of the part in service, particularly in applications subject to wear, corrosion or specific functional requirements.
This control throughout the process is essential to ensure that each component meets the requirements defined for its application.
AN INTEGRATED SOLUTION FOR PRECISION METAL COMPONENTS
ETMA works according to an integrated production logic, bringing together different industrial capabilities that make it possible to support the development and production of metal components from the initial stage through to series production.
ETMA also follows a horizontal production strategy, with several transformation processes installed in-house, which can be selected not only according to the geometry of the component, but also according to the final application and the most suitable mechanical and metallurgical properties for the function of the component.
In this context, sintering can be combined with other processes and complementary operations, contributing to a more complete response. For the client, this integration means greater technical coordination, better dimensional control, fewer dispersed operations and greater confidence in the final quality of the component.
It is precisely in this combination of process, technical knowledge and industrial capability that sintering gains value: not as an isolated operation, but as part of a more efficient production solution, adapted to the challenges of today’s industry.
This investment in sintering is also aligned with ETMA’s innovation strategy. The company leads the SINT3R project, developed in co-promotion with CTCV and the University of Aveiro, which seeks to valorise industrial metal waste — such as steel shavings and copper/brass alloy waste — by requalifying it into metal powders for sintering processes.
This approach reinforces the potential of sintering not only as an efficient production process, but also as a technology that contributes to a more sustainable industry, by promoting better use of raw material, waste reduction and the development of high added-value technical components.
INDUSTRIAL APPLICATIONS OF SINTERING
Sintering can be applied to the production of different precision metal components, especially when there is a need for dimensional accuracy, repeatability and efficient use of material.
It is a particularly suitable solution for small and medium-sized technical parts, components with complex geometries, functional elements produced in series, parts with strength requirements and components that can benefit from complementary sizing, heat treatment, surface treatment or inspection operations.
Its versatility makes this process relevant for several industrial sectors, whenever the objective is to transform metallic material into functional, consistent and competitive components.
EFFICIENT TECHNOLOGY, CONSISTENT PRECISION
Sintering shows that industrial innovation is not always about producing faster. Very often, it is about producing better: with less waste, greater control and more efficiency throughout the process.
At ETMA, this new capability strengthens the ability to develop precision metal solutions, prepared to respond to projects where geometry, material, cost and final performance must be aligned.
Because, in industry, every component counts. And the way it is produced can make all the difference to its reliability, competitiveness and integration into the final product.
DOES YOUR PROJECT REQUIRE PRECISION METAL COMPONENTS, EFFICIENCY AND HIGH REPEATABILITY?
ETMA combines technical expertise, production capacity and integrated processes to support the development and production of demanding metal components — from the project stage through to series production.
Talk to us and discover how we can support the development of your next metal component.