Consolidation and shaping of grade powders is carried out using several methods, depending on the size, complexity, shape, and quantity of parts required. This article details the powder consolidation methods of carbide powders: uniaxial pressing, cold isostatic pressing, extrusion, green machining, and injection molding.

Machinability is more important in extending the applications of powder metallurgy (PM). This article provides an overview of the machining process and machinability measurement of PM steels. It discusses various approaches to improve machinability, including the closure of porosity, green machining, presintering, microcleanliness improvement, free-machining additives, microstructure modification, and improvements in tool materials. The effects of free-machining agents on machinability and the sintered properties of PM steels are also reviewed.

Ceramic-forming processes usually start with a powder which is then compacted into a porous shape, achieving maximum particle packing density with a high degree of uniformity. This article compares and contrasts several forming processes, including mechanical consolidation, dry pressing, cold isostatic pressing, slip casting, tape casting, roll compaction, extrusion, and injection molding. It describes the advantages, equipment and tooling, and material requirements of green machining, the machining of ceramics in an unfired state with the intent of producing parts as close to as possible to their final shape. The article also provides useful information on drying methods, shrinkage, and defects as well as the removal of organic processing aids such as dispersants, binders, plasticizers, and lubricants.