Honoring Our Past.
Re-imagining the Future.
North Central Pennsylvania might not be the first place that comes to mind when you think of cutting-edge industrial processes, but this region has for decades been a quiet powerhouse in the world of powder metallurgy and pressed materials. What began as an extension of its rich mining heritage evolved into a highly specialized industry, producing critical components for everything from automobiles to medical devices.
​
The story of powder metallurgy in this region is deeply intertwined with its natural resources and the ingenuity of its people. Early industrial endeavors in North Central Pennsylvania, particularly around areas like St. Marys, Ridgway, and DuBois, were rooted in iron ore extraction and traditional metalworking. However, as the 20th century progressed, new methods of material production began to emerge, promising greater efficiency and the ability to create complex shapes with superior properties.
The Dawn of Powder Metallurgy in the Region
​The precise origins are somewhat debated, but the mid-20th century saw the significant growth of powder metallurgy in North Central Pennsylvania. Several factors contributed to this boom:
​
-
Proximity to Raw Materials: While direct iron ore mining waned, the region's existing infrastructure and expertise in handling metallic materials provided a natural springboard for powder production.
​​
-
Industrial Innovation: Companies recognized the advantages of powder metallurgy, such as reduced waste, lower energy consumption compared to traditional casting or forging, and the ability to produce parts with controlled porosity and unique material combinations.
​​
-
Skilled Workforce: The existing manufacturing base provided a ready supply of skilled labor adaptable to the new techniques.
One of the foundational companies in the region's powder metallurgy story is arguably MPM (Magnetic Powdered Metals), which later became part of the Hoeganaes Corporation and then GKN Sinter Metals. While Hoeganaes focused on producing the metallic powders themselves, other companies in the area specialized in pressing and sintering these powders into finished parts.​
North-Central Pennsylvania's Pressed Materials Industry is rooted in the late 1800s production of pressed carbon in St. Marys, Pennsylvania, to make metal graphite brushes for the then-emerging electric power industry. Carbon pressing techniques developed to make these parts were modified to make carbon electrodes for deployment in electric arc steel furnaces in Pittsburgh. Then, inspired by porous carbon bearings exhibited at the 1932 World’s Fair in Chicago, carbon producers began exploring the growing possibilities of pressed materials after World War II.
​
Excerpt from Passmore et al. Journal of Technology Studies
Growth and Diversification
The industry truly began to flourish in the latter half of the 20th century. Companies like Brockway Pressed Metals (later part of Symmco Inc.), Keystone Powdered Metal Company, and numerous others established strong presences. These companies specialized in various aspects of the powder metallurgy process, from pressing and sintering to coining and infiltration, producing a vast array of components:​​
​
-
Automotive Parts: Gears, bushings, and structural components for the rapidly expanding automotive industry were, and still are, a major application.
​​
-
Consumer Goods: Pressed materials can be found in components for appliances, power tools, lawnmowers and many other commercial products.
​​
-
Industrial Machinery: Bearings, cams, and other precision parts are made using pressed materials for various industrial applications.
​​
-
Specialized Applications: As the technology advanced, so have applications, including components for medical devices, aerospace, and defense.
The region became known for its expertise in producing complex, high-precision powdered metal parts. This reputation continues today as the industry adapts to new technologies, applications, and global markets.
Today, pressed materials are finding new uses and applications, such as in the GE Aviation's GE9X engine, which is equipped with more than 200 metal additively manufactured turbine blades. The engine is the first of its kind to receive FAA certification, having endured 8,000 cycles of testing.
The printed blades are 30% lighter than traditionally manufactured counterparts and contribute to a 10% increase in fuel efficiency compared with the GE90 engine. GE Additive say the turbine blades cannot be made with any other manufacturing process.
The Future of Pressed Materials in North Central Pennsylvania
​Today, North Central Pennsylvania remains a vital hub for the powder metallurgy and pressed materials industry. Companies in the region continue to innovate, producing high-quality, cost-effective components that are essential to countless industries worldwide.
The legacy of ingenuity and adaptability that began with the region's early industrial roots continues to drive its success, ensuring that North Central Pennsylvania remains at the forefront of material science and manufacturing. From humble beginnings processing iron ore, the region has truly pressed its way into a position of global leadership in advanced materials.
