Case Studies

Process: CNC Press

Density: 6.8 g/cm3

Material: FLC-4805

End Use and Function

The customer had started moving forward with 2 metal guides inside a plastic frame. This design had failed at a critical time in the launch plan. PM was brought in as the design of choice technology that was able to pass all testing and requirements in an accelerated timeline. The anti-rotation sleeve is part of the new drive by wire brake system introduced in production automotive vehicles for model year 2021. This evolution of vehicle safety in enhancing the previous ABS and traction control systems by actuation of the brake system with an electric motor vs the traditional vacuum boosted power brake pedal.

Fabrication

Density control is critical in minimizing form error through sintering and is formed using our CNC press. Maintaining part integrity through the compaction and ejection process is critical due to the thin cross section where the flange joins the legs. Parts are sinter hardened with custom design plates to support the legs to minimize distortion, maintaining tight perpendicularity and cylindricity, prior to a fully automated final hard turn machining operation controlling dimensions with 0.03 mm/0.0012”. The part is 100% verified during the machining operation for the OD fit and nut slot as well as resonant crack verification after sinter to ensure good product in this critical application.

Results

System provides enhanced safety combined with road and traffic monitoring systems to apply brakes before the driver can react in emergency conditions and is key to the development of future autonomous vehicles.