There are many factors that will help P/M continue to be a cost effective alternative to more traditional metal forming technologies. Among these factors are consistency of properties and dimensions during the manufacturing process. Material handling, mix composition, and manufacturing environment all affect the performance of P/M mixes. This paper will discuss how mixes bonded using the Starmix™ process can improve the consistency of dimensions and properties by reducing the possibility of segregation of mix constituents. The improvements in component consistency were analyzed during production of typical P/M.