Powder Metallurgy Pressing: Design Considerations

Avoid sections whose cross-section increases along the pressing direction; this helps compaction and ejection.

Use radiused or chamfered transitions between walls instead of sharp corners to avoid stress concentration in the tool and the powder compact.

Avoid grooves and blind holes on side walls; they complicate compaction or require additional tool components.

Prefer simple, symmetrical shapes. Large cross-section changes, narrow slots and spherical features increase tooling and pressing difficulty.

Avoid locally thin walls, which complicate powder filling and can cause cracks during pressing.

Part weight is a key control point in pressing: inconsistent fill causes weight variation that directly affects final part performance. Part surfaces should be kept clean of residual powder and impurities and stored properly after pressing.