The annual ‘State of the PM Industry in North America’ address was presented by MPIF President Michael Stucky at PowderMet 2024, held in Pittsburgh, USA, June 17-19. During his overview of the wider industry, Stucky also reported on Metal Injection Molding, as well as metal Additive Manufacturing, Hot/Cold Isostatic Pressing (CIP/HIP) and of course Press and Sinter PM.
Regarding MIM and AM powders, Stucky stated, “Producers entered unchartered waters in 2023, but most expect it to be an anomaly and not reflective of its long-term trajectory. Feedstock producers, who are large powder consumers, maintained significant inventories of raw powder to ensure consistent supply for customers.”
“At the same time, parts makers worked through unusually high inventories that resulted from over purchasing in 2021-2022, a reaction to disrupted powder supplies. Adding to the unstable conditions were declining orders throughout the year. The unusual circumstances affected both powder and feedstock producers,” he said.
Spherical stainless steels and low-alloy steels are the primary MIM and AM materials, but considerable research and development has resulted in successful components from aluminium, copper, titanium, tungsten, and an array of other metal powders and alloys, he stated.
“North American metal powder consumption for AM is estimated to have increased by 10% in 2023 to 434,088 kg (957,000 lb). However, the combined MIM and AM metal powder shipments decreased by an estimated 10% to 3,706,757-3,963,944 kg (8,172,000-8,739,000 lb),” continued Stucky.
“Some industry insiders believe the decrease in shipments for MIM could be even greater,” warned Stucky, “but all expected a correction during 2024-2025.”
Regarding markets for MIM in North America, Stucky stated that the medical and firearms sector continued to be the prime consumers of MIM components, but the demand for firearms had steadily decreased over the past 3 years. However, Stucky also reported that general industrial applications and automotive MIM components have continued to increase each year.
Following the responses gained from MIM powder and feedstock suppliers, Stucky said the outlook is positive for the future. This positive view includes the stability of standard offerings like stainless steels, low-alloy steels, and titanium alloys. “There has been increased interest in superalloys that are coming into commercialisation,” added Stucky.
The Metal Injection Molding Association’s Standards Committee is currently reviewing its first titanium standard.
With regard to the demand for molding equipment, this was said to be stable as overall production demands are being met by existing equipment. MIM furnace demand, however, is continuing to grow reported the MPIF president. “Automation is expected to increase as skilled workers become scarcer,” he added.
Stucky pointed out that there are a considerable number of MIM manufacturers that have a presence in AM, primarily utilising Binder Jet technology due to its process similarities. “As MIM and metal AM continue to be identified as the solution, additional opportunities in medical and dental markets will develop,” he said.
Wrapping up, Stucky stated, “The PM industry will need to continue to invest in the development of our people, acknowledging and valuing their contributions to its success, and encouraging them to share their ideas. The industry must respond to the changing needs and demands of existing and potential customers with agility and ingenuity, while maintaining higher value than competing manufacturing technologies.”
“We have a lot to look forward to as we advance the PM technology,” Stucky concluded.