I served 20 years in the auto industry as well. And one must be VERY smart about alloys and manufacturing processes. I want a carbon fiber chassis, brakes and clutch vehicle but I do not have the funds so... my car is made just like everyone else's car. [emoji38]
If you design the part with MIM in mind there is not usually an issue, as I've stated.
In aerospace they use HIP and MIM but they also use various alloys that cannot be formed otherwise to make an even stronger part. Same with knife blades (e.g., CPM 3V, ELMAX, etc.). I'm not sure what their limit is for porosity, density, etc., but you lose some of the cost benefit but the mechanical properties exceed what you could normally get so it "does not matter".
When I was living in Detroit we scanned parts and took the files to shops who would create them the way we wanted - CNC from forging, cryo, Melonite, DLC coat.
It was fun times!
Look at the Extractors of modern pistols that are MIM (except Glock): large cross section, no sharp radii - good opportunity for MIM. Part of Glock's issues with the Gen 4 was horribly produced Extractors (they were MIM and the worst I had ever seen). They are also a great opportunity for near net shape production yet are an engineering challenge to do properly (complex geometry in a very small package).
Hint: buy an Apex Tactical Failure Resistance Extractor. [emoji6]
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