Manufacturing

Depending on the part size, configuration, material and porosity required, several manufacturing techniques are used in the industry:

Axial pressing and sintering
This technique is similar to the common sintered part manufacturing method. The main differences are lower forming pressure and tighter powder sieve cuts. After pressing, the green porous parts are heated in a controlled atmosphere to a temperature below the melting point of the considered alloy to achieve bonding of the particles.

Powder rolling and sintering
Porous sintered sheets in various thicknesses are produced by direct powder rolling before sintering. The specified porosity is obtained by adjusting the particle size and the rolling pressure. The sintered porous sheets can be cut, rolled, welded, etc in many different forms. 

Isostatic compaction and sintering
In this process, the compaction pressure is applied uniformly to a deformable container holding the metal powder to be pressed. It is used for parts with a large length-to-diameter ratio. The green parts are sintered in the normal way.

MIM and sintering  
Porous parts can be produced by Metal Injection Moulding (MIM). The particles are blended with a large amount of binder to form a paste that is injected into moulds at a high pressure. This works in the same way as plastic or polymer injection moulding. Special de-binding, sintering and sizing equipment is necessary to control the significant shrinkage that occurs due to binder removal. Very complex part shapes can be achieved by this method.