Customer Background:
- Global automotive OEM client requiring precision gears fordrivetrain assemblies.
Initial Requirement :
- Conventional gear manufacturing via machining from bar stock, whichwas costly, time-consuming, and had longer production cycles.
Challenge :
- Reduce manufacturing cost and cycle time while meeting stringent technicalperformance and dimensional accuracy for high-volume automotive gear production.
AMSOL Solution :
- Proposed shift to powder metallurgy (PM) sintered gear technology.
- Utilized metal powder compaction followed by controlled sintering to form near-netshape gears.
- Secondary finishing, heat treatment, and quality checks ensured gears met operationalstrength and durability requirements.
- Emphasized high precision tooling and process control during compacting and sinteringstages.
Key Advantages of Sintering Process at AMSOL :
- Significant cost reduction compared to traditional machining due to less raw materialwaste and fewer machining steps.
- Faster production cycles , enabling rapid meeting of demand.
- Enhanced mechanical properties and dimensional uniformity suited for automotivestandards.
- Ability to produce complex gear geometries efficiently and in large volumes.
Results :
- Customer accepted samples and approved functional compliance.
- AMSOL secured a long-term order for 1 million gear parts over 5 years.
- Manufacturing scalability achieved with continuous quality assurance.
Conclusion :
- AMSOL’s powder sintering gear solution exemplifies innovative manufacturing to drivecost savings and meet OEM stringent technical needs.
- The successful case reinforces AMSOL’s position as a trusted long-term manufacturingpartner in the automotive supply chain.