Products · 03
Structural parts.
Sintered structural parts are self-lubricating and durable. The porous construction gives high strength-to-weight ratios for equipment requiring minimal maintenance.
01Design economics
Complexity is cheap. Levels are not.
This is the single most useful thing to know before drawing a sintered part. An odd contour in plan view costs nothing extra on the part — only on the tool. Steps in the pressing direction are different: every level adds tooling complexity and pulls density down.
Levels
Levels cost extra and limit density. One level is easiest; two and three levels are possible, at a price.
Contour
Contour like an odd shape does not cost extra on the part, just on tooling. Complexity in plan view is close to free once the tool exists.
Density
High density limits complexity in design. The density target and the geometry have to be agreed together, not in sequence.
- Tool-relatedIT 9
- After sintering. Can be improved with different types of finishing e.g. repressing, cutting-machining and roll polishing.
- In direction of pressingIT 13
- Large shallow cavities make it easier and vice versa.
02Remember
Four rules worth designing around.
Callo publishes these in its own design guidance. They are short, and they decide whether a part is easy or expensive.
- 01
Hold down projected surface in direction of pressure.
- 02
When you save weight, do it straight away so you save surface and don’t create another level.
- 03
Avoid thin sections less than 1.5 mm — thin stamps and fill problems.
- 04
Bit must come out of the tool — can be biggest in the middle.
Gears are a very good sinter product, but there are limitations on small modules like 0,5 and lower.
01Why it works
What this gives an engineer.
- No or modest tool costs — low start-up cost compared with forging or die casting
- Plenty of freedom to make changes to the design
- Complex contours cost nothing extra on the part — only on the tooling
- Material characteristics from just above die-cast zinc to almost as good as forged
- Copes with transverse grooves and channels that casting struggles with
02Where it ends up
Typical applications.
- Yoke for a truck engine
- Part for flywheel for chainsaw
- Wheelchair part
- Impeller, water pump on truck engine
- Gear segment, office machine
- Gear, lawnmower
- Clutch for chainsaw
- Bevel gear, office chair
Application examples published by Callo — real parts the company has produced, listed as Callo lists them.
Engineering support
Get the geometry right before the tool is cut.
The earlier Callo becomes involved in the design process, the easier it is to optimise geometry, material properties, tooling and production economics.
Resources
Documents and drawings.
- Request
Design for sintering guide
Target image, density, tolerances, levels and contour.
- Request
Material data
Density-dependent and non-density-dependent characteristics.
- Request
Method comparison
Sinter steel against machining, forging, stamping and casting.
On a live site these would download directly from here. In this demo they route to the contact page.
04Custom components
Have a component in mind?
Send Callo your drawing or your requirements and start a technical discussion. The earlier the conversation starts, the more there is to gain — geometry, material, tooling and production economics are still open.
- 01
Send what you have
Share the available part information directly with Callo and confirm the preferred drawing or model format.
- 02
Talk to someone technical
Callo publishes direct phone and email contacts for questions and orders.
- 03
Get a real answer
Discuss feasibility, materials and tooling requirements with Callo before production.
Demo page only — file formats and delivery workflow require Callo approval