Volumetric Powder Metallurgy 2025: Discover the Breakthroughs Set to Redefine Manufacturing

Table of Contents

• Executive Summary: Key Insights for 2025 and Beyond
• Market Size, Growth Projections, and Regional Trends (2025–2030)
• Breakthrough Technologies in Volumetric Powder Metallurgy
• Major Industry Players and Collaborations (Citing Company Websites)
• Applications Across Aerospace, Automotive, Medical, and Energy Sectors
• Materials Science Innovations: Alloys, Ceramics, and Composites
• Manufacturing Process Advances and Automation Integration
• Sustainability and Circular Economy Impacts
• Challenges, Regulatory Developments, and Standardization Efforts
• Future Outlook: Strategic Opportunities and Emerging Markets
• Sources & References

Executive Summary: Key Insights for 2025 and Beyond

Volumetric Powder Metallurgy (VPM) is poised for significant advances in 2025 and the coming years, as the sector benefits from technological innovation, expanding application domains, and intensifying efforts to improve sustainability and throughput. VPM, characterized by the production of three-dimensional components through the compaction and sintering of metal powders, is increasingly adopted across industries such as automotive, aerospace, energy, and medical, driven by the demand for lightweight, high-performance, and cost-effective solutions.

Key developments in 2025 are centered on the integration of digital tools and automation for process control, enabling tighter tolerances and more consistent part quality. Leading industry participants are applying advanced data analytics and real-time monitoring to their powder metallurgy operations. For example, GKN Powder Metallurgy has expanded its digitalized production facilities worldwide, focusing on process optimization and traceability to meet the stringent requirements of electric vehicle and e-mobility markets. Similarly, Höganäs AB is leveraging its digital manufacturing platform to enhance the efficiency of volumetric sintered component production, supporting both traditional and emerging applications.

Material innovation is a central theme for the near future. In 2025, alloy development and powder customization are expected to accelerate, with suppliers like Höganäs AB and Carpenter Technology Corporation investing in high-performance powders tailored for additive manufacturing and high-volume press-and-sinter processes. These materials offer improved mechanical properties, corrosion resistance, and design flexibility, supporting the shift toward electrified powertrains and lightweighting initiatives in transportation sectors.

Sustainability goals are also shaping the VPM landscape. Producers are increasingly focused on recycling and circularity in powder production and end-of-life component recovery. Initiatives by GKN Powder Metallurgy and Höganäs AB include closed-loop powder management and the use of renewable energy in their manufacturing processes, aligning with the environmental targets of key customer industries.

Looking ahead, the outlook for volumetric powder metallurgy in the next few years is robust, with anticipated growth in markets requiring high-volume, precision components. Applications in electric vehicles, renewable energy, medical implants, and industrial automation are expected to drive demand. The ongoing development of digital and material technologies, combined with a strong emphasis on sustainability, will position VPM as a critical manufacturing technology for the modern industrial landscape.

Market Size, Growth Projections, and Regional Trends (2025–2030)

Volumetric powder metallurgy (VPM) is undergoing a phase of dynamic growth, driven by increasing demand for high-performance components in automotive, aerospace, energy, and medical sectors. As of 2025, the global volumetric powder metallurgy market is valued at an estimated $12–14 billion, with notable growth stemming from applications requiring complex geometries, high material utilization, and enhanced material properties. The expansion of additive manufacturing—especially binder jetting and selective laser sintering—has broadened the scope and commercial viability of VPM processes.

Looking ahead to 2030, industry stakeholders forecast a compound annual growth rate (CAGR) of 6–8%. This growth is underpinned by increased adoption in electric vehicle (EV) powertrains, lightweight aerospace structures, and medical implants, where volumetric approaches offer cost-effective alternatives to traditional subtractive techniques. For instance, GKN Powder Metallurgy is scaling up production capacity to meet projected demand from automotive OEMs transitioning to electric propulsion and hybrid platforms. Similarly, Höganäs AB is investing in expanding its portfolio of high-performance powders tailored for advanced VPM applications across multiple sectors.

Regionally, Asia-Pacific is poised to maintain its leadership in market share through 2030, buoyed by robust manufacturing ecosystems in China, Japan, and South Korea. Government initiatives supporting advanced manufacturing and local supply chains—such as China’s “Made in China 2025” strategy—are accelerating adoption of VPM technologies. In Europe, efforts to decarbonize automotive and industrial supply chains are catalyzing investment in powder metallurgy, with companies like Sandvik driving innovation in sustainable metal powder production. North America, meanwhile, is witnessing growth driven by aerospace and defense applications, with Carpenter Technology Corporation leveraging its expertise in specialty alloys for additive manufacturing and volumetric consolidation processes.

• The automotive segment is forecast to remain the largest end user of VPM, supported by the shift to electrification, demand for lightweighting, and high-volume component production.
• Aerospace and medical sectors are projected to exhibit the fastest CAGR, as VPM enables design freedom and precision for complex, safety-critical parts.
• Innovation in powder production—such as atomization, recycling, and alloy development—will be a key differentiator, with major players investing in greener and more efficient powder supply chains.

Overall, volumetric powder metallurgy is set for robust expansion through 2030, with regional dynamics shaped by manufacturing policies, technological advancements, and sector-specific growth drivers. The next five years will see intensified competition, strategic partnerships, and a focus on sustainable production practices as the industry evolves.

Breakthrough Technologies in Volumetric Powder Metallurgy

Volumetric Powder Metallurgy (VPM) is undergoing a period of rapid technological evolution in 2025, driven by advances in additive manufacturing, powder production, and process control. One of the most significant breakthroughs in VPM is the integration of high-precision binder jetting and laser-based additive manufacturing systems, which allow for the rapid creation of complex, high-density metal parts directly from powder. For example, GE Additive has introduced new binder jetting platforms capable of producing components with improved volumetric density and mechanical properties, reducing the need for extensive post-processing.

Another notable advancement is in powder atomization and classification. Companies such as Höganäs AB have developed advanced water and gas atomization techniques, resulting in powders with highly controlled particle size distributions and morphologies. These powders not only enhance the densification during sintering but also improve consistency in volumetric builds, which is critical for aerospace and automotive applications. Furthermore, Höganäs AB has expanded its additive manufacturing powder portfolio in 2025, focusing on materials specifically engineered for volumetric builds.

Process control and in-situ monitoring technologies are also transforming VPM. Real-time feedback systems integrated into additive manufacturing machines, such as those developed by EOS GmbH, enable the monitoring of layer-by-layer deposition, powder spreading, and densification. This ensures consistent volumetric quality and allows for the early detection of defects, significantly reducing material waste and production time.

Hybrid manufacturing approaches are another frontier. Renishaw plc has launched hybrid machines that combine traditional subtractive methods with powder-based additive techniques, maximizing the geometric complexity achievable while maintaining tight volumetric tolerances. These systems are particularly valuable for industries demanding both high performance and design flexibility.

Looking ahead to the next few years, continued innovation in powder metallurgy is expected to focus on scalability, sustainability, and digital integration. Industry leaders are investing in closed-loop recycling of unused powders and energy-efficient sintering technologies, as seen in recent initiatives by GKN Powder Metallurgy. Digital twins and AI-driven process optimization are also anticipated to become mainstream, enabling further advances in volumetric accuracy and production efficiency.

Major Industry Players and Collaborations (Citing Company Websites)

Volumetric powder metallurgy (PM) is entering a period of intensified industrial collaboration and investment as companies seek to address the growing demand for high-performance, near-net-shape parts in automotive, aerospace, and energy sectors. In 2025, established leaders and innovative newcomers are driving the field forward through technology alliances, expansions, and strategic partnerships.

Key Producers and Activities (2025):

• Höganäs AB remains a global frontrunner in metal powders, with ongoing investments in volumetric PM capabilities. The company is focusing on sustainable production, introducing new energy-efficient atomization processes and digital powder management systems to optimize large-scale, high-precision 3D part manufacturing (Höganäs AB).
• GKN Powder Metallurgy continues to expand its global footprint, notably through partnerships with automotive OEMs and aerospace suppliers to co-develop complex volumetric PM components. In 2024–2025, GKN has highlighted collaborations focused on electrification and light-weighting, leveraging advanced powder atomization and binder jetting technologies (GKN Powder Metallurgy).
• Carpenter Technology Corporation is strengthening its additive manufacturing and powder production capabilities, emphasizing high-purity, specialty alloys for volumetric PM. Recent investments in state-of-the-art powder atomization plants aim to support aerospace and medical customers with demanding volumetric tolerances (Carpenter Technology Corporation).
• Praxair Surface Technologies (now a part of Oerlikon AM) has been scaling up its metal powder production, targeting the volumetric PM market with alloys optimized for additive manufacturing and sinter-based technologies. The company is collaborating with aerospace and energy partners to develop new powder grades and post-processing solutions (Oerlikon AM).

Collaborative Outlook (2025 and beyond):

• Joint R&D initiatives between powder suppliers and OEMs are expected to accelerate the adoption of volumetric PM for lightweight electric vehicle (EV) components and turbine applications.
• Industry working groups, such as those coordinated by the Metal Powder Industries Federation (MPIF), are focusing on standardization and qualification of volumetric PM parts to streamline certification in critical sectors.
• Increased cross-sector partnerships—especially between aerospace, medical, and automotive industries—are anticipated, leveraging volumetric PM’s flexibility and efficiency for complex, multifunctional parts.

As major industry players invest in expanded production, digitalization, and collaborative R&D, volumetric powder metallurgy is poised for significant growth and diversification through 2025 and the following years.

Applications Across Aerospace, Automotive, Medical, and Energy Sectors

Volumetric powder metallurgy (VPM) continues to gain substantial traction across critical sectors such as aerospace, automotive, medical, and energy, driven by its ability to enable complex geometries, enhanced material properties, and significant material savings. As of 2025, industry leaders are actively incorporating VPM technologies—particularly additive manufacturing (AM) approaches like binder jetting, selective laser melting (SLM), and electron beam melting (EBM)—to address evolving design and performance requirements.

• Aerospace: The aerospace sector remains a primary adopter of VPM, leveraging the technology to produce lightweight, high-strength components with intricate internal structures that are unachievable by traditional methods. Notably, Boeing and GE Aerospace have expanded the use of VPM for critical engine parts and structural elements, citing improved fuel efficiency and reduced lead times as key benefits. In 2024, Airbus announced the qualification of new VPM-produced titanium airframe components, targeting serial production for next-generation aircraft platforms.
• Automotive: Automotive manufacturers are rapidly integrating VPM to address both electrification and lightweighting challenges. BMW Group has implemented volumetric powder bed fusion techniques for prototyping and small-series production of drivetrain and chassis parts, achieving up to 50% weight reduction compared to conventionally manufactured counterparts. Similarly, Ford Motor Company is piloting VPM for custom tooling and functional parts, aiming to increase production flexibility and decrease time-to-market for new models.
• Medical: In the medical field, VPM is enabling the creation of patient-specific implants and advanced surgical instruments. Smith+Nephew and Stryker are utilizing VPM, particularly electron beam melting, to manufacture porous bone implants that promote osseointegration and reduce rejection risk. Regulatory approvals for VPM-produced devices are on the rise, reflecting increasing confidence in the technology’s reliability and traceability.
• Energy: The energy sector, particularly in nuclear and oil & gas, is adopting VPM to fabricate corrosion-resistant, high-performance components. Siemens Energy is deploying VPM for gas turbine parts, which demand precise material control and resistance to extreme environments. The ability to rapidly prototype and produce spares on demand is enhancing operational uptime and reducing maintenance costs.

Looking ahead, the convergence of VPM with digital design tools and quality assurance systems is expected to further expand its application scope. As powder quality, process monitoring, and post-processing capabilities advance, the penetration of VPM into mainstream production pipelines is anticipated to accelerate over the next several years, solidifying its role in the transformation of manufacturing across these sectors.

Materials Science Innovations: Alloys, Ceramics, and Composites

Volumetric powder metallurgy (VPM) is poised for significant advances in 2025 and the near future, driven by ongoing innovations in materials science, particularly in alloys, ceramics, and composites. The industry is witnessing a surge in the adoption of VPM processes, as they enable the fabrication of complex, high-performance parts with tailored microstructures and minimized material waste.

In the realm of advanced alloys, leading manufacturers are continuing to develop new powder compositions for aerospace and energy applications. For example, Höganäs AB has expanded its portfolio of gas-atomized powders, focusing on nickel-based superalloys and high-entropy alloys designed for superior mechanical properties and corrosion resistance. Such innovations cater to the growing demand for lightweight, durable components in high-stress environments.

Ceramic materials are also benefiting from VPM advancements. Companies like Tosoh Corporation are producing ultra-fine ceramic powders based on zirconia and alumina, which are increasingly used to create components with exceptional wear and thermal resistance. The ability to control particle size and distribution in these powders is critical for achieving high-density, defect-free ceramic parts, a challenge that VPM is uniquely suited to address.

Composite materials represent another area of active development. For instance, GKN Powder Metallurgy is working on metal matrix composites (MMCs) that combine metallic powders with ceramic reinforcements, resulting in materials that offer both strength and toughness. These composites are particularly attractive for automotive and industrial applications where performance-to-weight ratios are crucial.

The integration of digitalization and process monitoring within VPM is anticipated to accelerate over the next few years. Companies such as GE Additive are investing in real-time quality control and simulation tools, enabling the optimization of powder characteristics and sintering parameters. This digital transformation is expected to improve consistency and scalability for high-value components across multiple sectors.

Looking ahead, the outlook for volumetric powder metallurgy in materials science remains robust. As manufacturers focus on sustainability and resource efficiency, VPM’s ability to reduce waste and enable the use of recycled powders is likely to gain further traction. The next few years are expected to bring continued innovation, with collaborative efforts between powder producers, equipment manufacturers, and end-users driving the development of novel materials and applications.

Manufacturing Process Advances and Automation Integration

Volumetric powder metallurgy (VPM) is undergoing significant transformation in 2025, driven by advances in process automation, quality control, and integration with digital manufacturing platforms. The contemporary landscape is marked by the increasing adoption of high-throughput, automated powder handling and compaction systems, as well as the implementation of Industry 4.0 principles to enable real-time monitoring and adaptive process control.

Leading powder metallurgy equipment suppliers have introduced new generations of fully automated presses and volumetric dosing units, designed to improve precision and repeatability in the compaction stage. For example, GKN Powder Metallurgy has deployed intelligent press systems featuring closed-loop feedback and in-line sensors that continuously monitor fill density, powder flow, and die wear, ensuring consistent part quality and reducing material waste. Similarly, Höganäs AB has focused on integrating automation into their powder delivery and mixing lines, leveraging robotics and machine vision to minimize human intervention and contamination risk.

Process data integration is another key trend. Manufacturers are increasingly linking their VPM lines with enterprise resource planning (ERP) and manufacturing execution systems (MES) to enable traceability from powder feedstock to finished components. Sandvik has reported the use of digital twins and predictive analytics within their powder production facilities, optimizing process parameters and forecasting maintenance needs to maximize equipment uptime and product consistency.

In parallel, sintering technologies are being upgraded for higher throughput and energy efficiency. Companies such as SACMI are offering continuous belt furnaces with precise temperature zoning and atmosphere control, compatible with automated loading and unloading systems, which facilitate seamless integration into fully automated VPM production cells.

Looking ahead to the next few years, the sector anticipates further convergence of VPM with additive manufacturing (AM). Hybrid systems capable of both volumetric powder compaction and selective laser sintering are in development, as companies seek flexible production lines suitable for both high-volume and customized parts. The ongoing refinement of process automation, combined with advanced inline inspection (e.g., X-ray CT and AI-driven defect recognition), is expected to push defect rates lower and enable qualification of VPM components in critical applications such as automotive electrification and medical devices.

Overall, the outlook for 2025 and beyond is marked by increasing automation, data-driven manufacturing, and the expansion of VPM into new markets, supported by the continued innovation efforts of industry leaders directly involved in the sector.

Sustainability and Circular Economy Impacts

Volumetric powder metallurgy (VPM) is poised to play a pivotal role in advancing sustainability and circular economy objectives in 2025 and beyond. By utilizing near-net-shape manufacturing and minimizing material waste, VPM aligns with global efforts to reduce the environmental footprint of metal production and fabrication. Major industry players are intensifying efforts to increase the recyclability of metal powders and to integrate scrap materials into new production cycles. For example, Höganäs AB has set ambitious targets to increase the recycled content in its powder metallurgy products, aiming for a significant reduction in energy use and greenhouse gas emissions per ton of powder produced by 2030.

Several VPM processes, such as additive manufacturing and hot isostatic pressing, offer unique sustainability advantages by enabling the direct reuse of unsintered powder and offcuts. GKN Powder Metallurgy reports that up to 95% of input material can be transformed into finished parts using their advanced powder-based technologies, drastically reducing waste compared to traditional subtractive manufacturing methods. Additionally, these processes often require lower processing temperatures and shorter production cycles, further conserving energy and resources.

The circular economy potential of VPM is also being realized through closed-loop supply chains. Carpenter Technology Corporation highlights its initiatives to collect and recycle metal scrap and swarf from customers, reprocessing it into high-quality powders suitable for critical component manufacturing. Similarly, Rio Tinto Metal Powders has launched programs to reclaim and refine used powders from additive manufacturing operations, reducing the demand for virgin raw materials.

Looking forward to the next few years, the VPM sector is expected to further integrate renewable energy sources into powder production and sintering processes. Companies such as Höganäs AB are piloting hydrogen-based reduction technologies, which have the potential to eliminate fossil-fuel-derived CO₂ emissions entirely from powder manufacturing. As regulatory pressures and customer demand for greener materials intensify, the adoption of sustainable VPM practices is projected to accelerate, positioning powder metallurgy as a cornerstone of the metals industry’s circular transition.

Challenges, Regulatory Developments, and Standardization Efforts

Volumetric powder metallurgy (VPM) is advancing rapidly, but the sector faces notable challenges related to process consistency, powder quality, regulatory compliance, and standardization—issues that are drawing substantial attention in 2025 and are likely to shape the industry’s trajectory in the coming years.

One of the primary technical challenges is ensuring the uniformity and reproducibility of volumetric builds, especially as VPM is increasingly adopted for critical aerospace and medical applications. Variability in powder morphology, flowability, and purity can compromise part integrity and mechanical properties. Major producers such as Höganäs AB and GKN Powder Metallurgy are investing in advanced powder characterization and closed-loop process monitoring to address these issues, with ongoing initiatives to refine atomization techniques and real-time quality control.

From a regulatory perspective, the integration of VPM into highly regulated sectors introduces new complexities. For instance, the aerospace industry must adhere to rigorous material and process approvals governed by bodies like the Federal Aviation Administration (FAA) and the European Union Aviation Safety Agency (EASA). In 2024-2025, companies such as GE Additive have reported progress in qualifying VPM-produced components for flight hardware, but the path to certification remains arduous and time-consuming. Medical device manufacturers face similar hurdles, with a growing emphasis on traceability and powder batch validation to meet evolving ISO and ASTM standards.

Standardization efforts are gaining momentum to support broader industrial adoption. Organizations including ASTM International and SAE International have, as of 2025, expanded working groups focused on additive and powder-based manufacturing, issuing new and revised standards that target powder characteristics, process control, and part qualification. Collaborative projects involving industry consortia—such as the Metal Powder Industries Federation (MPIF)—are accelerating the harmonization of testing methods and data reporting requirements.

Looking ahead, the coming years will likely see intensified efforts toward digital traceability, with manufacturers leveraging machine learning and blockchain technologies for end-to-end process documentation. There is also strong industry consensus that the development of universally accepted VPM standards will be essential for scaling up production, simplifying supply chain qualification, and enabling regulatory bodies to streamline approval processes. As these challenges are addressed, the VPM sector is expected to expand into new markets and applications, supported by a more robust regulatory and standardization framework.

Future Outlook: Strategic Opportunities and Emerging Markets

The future of volumetric powder metallurgy (VPM) in 2025 and the coming years is characterized by strategic opportunities driven by evolving industrial demands, technological advances, and expansion into emerging markets. As manufacturers seek higher material efficiency and design flexibility, VPM’s capabilities—especially in additive manufacturing and high-value component production—are becoming increasingly critical.

Key players are actively expanding their global footprints and investing in next-generation powder production and shaping technologies. For instance, Höganäs AB, one of the world’s largest metal powder producers, continues to develop advanced alloy powders and digital solutions to meet stringent requirements in automotive, energy, and medical sectors. Their focus on sustainable production and circularity aligns with growing regulatory and customer emphasis on environmental responsibility.

Another important development is the surge in demand from electric vehicle (EV) and renewable energy applications. Companies such as GKN Powder Metallurgy are investing in specialized powders and sintered components for e-mobility, including high-performance soft magnetic composites and lightweight structural parts. This is supported by their recent expansion projects in North America and Asia, targeting localized supply chains for automotive OEMs.

In parallel, the adoption of binder jetting and direct energy deposition—core volumetric additive manufacturing processes—are accelerating. Carpenter Technology Corporation is scaling up production of atomized metal powders optimized for additive manufacturing, specifically for aerospace and medical device markets. Their collaborations with end-users aim to qualify new alloys and geometries previously unachievable with traditional methods.

Emerging markets in Asia-Pacific and Latin America are also poised for significant growth, driven by rapid industrialization and localization strategies. Powder Metallurgy Technology reports increased demand for VPM components in consumer electronics and industrial automation, with regional governments incentivizing domestic production of high-value metal parts.

Looking forward, digital integration—such as process monitoring, AI-powered design, and supply chain traceability—is set to play a transformative role in enhancing VPM efficiency and quality assurance. Industry collaborations and standardization efforts, led by organizations like the Metal Powder Industries Federation (MPIF), are expected to accelerate the adoption of best practices and foster market confidence.

Overall, the next few years for volumetric powder metallurgy will likely be marked by robust growth, deeper application penetration, and technological breakthroughs as stakeholders capitalize on strategic opportunities across both established and emerging markets.

Sources & References

• Carpenter Technology Corporation
• Sandvik
• GE Additive
• EOS GmbH
• Renishaw plc
• Carpenter Technology Corporation
• Oerlikon AM
• Metal Powder Industries Federation (MPIF)
• Boeing
• GE Aerospace
• Airbus
• Smith+Nephew
• Siemens Energy
• SACMI
• Rio Tinto Metal Powders
• ASTM International