Auto Parts Manufacturer Reduces Scrap Rate by 35%

The Challenge

A Tier-1 automotive parts manufacturer was experiencing consistently high scrap rates (up to 12%) in their powder metallurgy production line for sintered gears and structural components. The root cause was traced to inconsistent particle size distribution in their copper powder supply, which led to:

• Uneven green compact density during pressing
• Dimensional variation after sintering beyond tolerance
• Increased rework and secondary machining costs
• Delivery delays affecting downstream assembly lines

The Solution

LSBT's technical team analyzed the customer's production parameters and recommended our CU-EP dendritic copper powder with a tightly controlled particle size range of 5-15 µm. Key advantages included:

• Superior compressibility — dendritic morphology provides better inter-particle locking during pressing
• Consistent particle distribution — every batch tested with laser diffraction analysis
• Improved flowability — optimized for automated die filling systems
• High purity — Cu >99.5%, low oxygen content for clean sintering

The Results

After switching to LSBT's copper powder, the customer achieved a 35% reduction in scrap rate within the first quarter. Dimensional consistency improved to within ±0.02mm, eliminating the need for secondary machining on 90% of parts.

Long-Term Partnership

The supplier has been using LSBT copper powder for over two years with zero batch rejections. Our dedicated quality team provides COA (Certificate of Analysis) with every shipment and maintains a buffer stock for just-in-time delivery.