North America Powder Metallurgy Market Size & Outlook, 2025-2033

North America Powder Metallurgy Market Size

The North America powder metallurgy market size was valued at USD 2.77 billion in 2024 and is estimated to grow from USD 3.08 billion in 2025 to reach USD 8.08 billion by 2033, growing at a CAGR of 11.3% during the forecast period (2025–2033).

Powder metallurgy, often known as P/M, is a manufacturing process in which a metal powder with particular characteristics of size, shape, and packing is transformed into a solid, accurate, and high-performance shape. It is a highly developed method of producing reliable net-shaped components by combining elemental or pre-alloyed powders, compacting this blend in die, and then sintering or heating the pressed part in a controlled furnace atmosphere in order to bond the particles. This is a highly evolved method of manufacturing. Powder metallurgy involves a number of different operations, such as blending and mixing, pressing, and sintering.

The process makes efficient use of automated procedures, which result in relatively low levels of energy consumption, high levels of material utilisation, and low levels of capital expenditures. P/M allows for the fabrication of high-quality, complicated parts that can adhere to tight tolerances in a manner that is both inexpensive and efficient. This is one of the most significant benefits of P/M.

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North America Powder Metallurgy Market Growth Factors

Light Truck Production Hit A High Value

In 2020, light truck production reached a new high of nearly 80% of all vehicles produced in North America. This is great news for the PM industry because light trucks (pickups/large SUVs) account for an estimated average of 27.2 kg (60 lb) of PM per vehicle, followed by mid-size/crossovers at 18.1 kg (40 lb), and sedans at 9.1 kg (20 lb). Estimating HV and EV is difficult. Powder-forged connecting rods and PM main bearing caps are not commonly used in high-voltage applications. Estimated EVs range from 1.8 to 3.6 kg (4-8 lb) of PM.

Based on strong light truck sales and low HV and EV penetration, the estimated average weight in a 2020 North American passenger vehicle was 16.8 kg (37 lb), a 5.1 percent decrease from 2019. Many industry experts predict that without new applications, a greater acceptance of powder-forged connecting rods and PM main bearing caps in HV, and the result of fewer parts in an EV, the PM weight in passenger vehicles will decrease 1–2 percent annually.

According to several PM part manufacturers, the future of PM will be to supply value-added, near-net-shape parts made of cost-effective lean-alloy materials with high material utilization rates. To that end, powder manufacturers are improving and developing new materials with higher green strength, excellent machinability, and increased compressibility, as well as increasing the development and use of soft magnetic composites (SMC). SMC materials will play an important role in the future of electric vehicles, home appliances, and other electric devices.

Market Restraints

Cost of Producing A Product Using An Additive Manufacturing Process Exceeds the Cost of Producing

In recent years, there has been a significant increase in the use of additive manufacturing. Additive manufacturing is used in a variety of industries, including automotive, aerospace, machinery, electronics, and medical products. However, additive-manufactured products currently account for less than 1% of all manufactured products in the United States. As the cost of additive manufacturing systems falls, this technology has the potential to change the way consumers interact with producers.

The technology of additive manufacturing creates new opportunities for the economy and society. It allows for the customised production of strong, light-weight products, as well as designs that were previously not possible with previous manufacturing techniques. However, a number of obstacles may impede and slow the adoption of this technology. In many cases, the cost of producing a product using additive manufacturing processes exceeds the cost of producing a product using traditional methods.

Countries Insights

The North America powder metallurgy market is further segmented on the basis of countries into USA, Canada & Mexico.

North America is expected to be the largest powder metallurgy market. The powder metallurgy market in North America is expected to grow in the long run, owing to an increase in the number of 3D printers in terms of size, feature, and material compatibility. Markets are likely to be driven by factors such as the presence of significant competitors in the region and consumer spending power.

Material Insights

The North America market has been divided into titanium, nickel, steel, aluminium, cobalt, and others. The market is expected to be dominated by the steel segment. Sensor bosses, flanges, antilock sensor rings, and hot exhaust gas outlet fittings are expected to grow in the automotive industry as a result of stringent environmental regulations and rising consumer demand for long-lasting parts.

The North America market is divided into three processes: additive manufacturing, metal injection moulding, and hot isostatic pressing. The market is expected to be dominated by the additive manufacturing process segment.

Application Insights

The North America market has been divided into aerospace & defence, automotive, medical & dental, oil & gas, industrial, and others. The market is expected to be dominated by the aerospace and defence sector. The ability of the aerospace and defence industries to tolerate high initial costs and adapt to new technology is expected to drive their growth.

End Use Insights

The North America market has been divided into original equipment manufacturers (OEMs) and additive manufacturing (AM) operators. The market is expected to be dominated by OEMs. Adoption of metal additive manufacturing represents a lucrative opportunity for original equipment manufacturers. Large original equipment manufacturers, particularly in the aerospace industry, are heavily investing in metal 3D printing to produce aeronautical parts.

List of key players in North America Powder Metallurgy Market

1. Alpha Sintered Metal Inc.
2. BASF
3. Gkn Sinter Metals
4. C. Starck
5. Hitachi Chemicals Co. Ltd.
6. Hitachi Powdered Metals Co. Ltd.
7. Hoeganaes Corp.
8. Borgwarner Inc.
9. Capstan California
10. Dorst Technologies
11. Epson Atmix Corp.
12. Erasteel
13. Exone Co.
14. Federal-Mogul Corp.
15. Acupowder International
16. Advanced Materials Technologies Pte Ltd.
17. Advanced Metalworking Practices Llc
18. Fine Sinter Co. Ltd.
19. Fukuda Metal Foil and Powder Co. Ltd.

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Recent Developments

• January 2022, Diego Laurent has been named Chief Executive Officer of GKN Powder Metallurgy, effective immediately. Diego Laurent leaves his position as GKN Powder Metallurgy's Chief Financial Officer, which he has held since 2018.
• May 2022, Desktop Metal, Inc., a global leader in additive manufacturing technologies for mass production, announced today that it will exhibit a historic collection of more than 300 3D printed production parts at RAPID + TCT, North America's largest and most influential AM event, May 17-19 in Detroit, alongside production-capable printing platforms for metals, polymers, elastomers, ceramics, composites, and upcycled wood materials.