Thermal wave radar imaging (TWRI) was developed to detect manufacturing cracks in automotive powder metallurgy components (transmission sprockets) in their green (unsintered) state. The crack detection capability of the TWRI phase was validated by two sets of cracked/crack-free green and sintered sprockets which were sectioned after TWRI measurements. An automatic defect recognition (ADR) TWR image processing method was also developed to differentiate cracks from local defects. Measurement results demonstrated that TWRI is superior to conventional lock-in thermography imaging (LITI) in both flaw detection resolution and speed, and thus is a viable green-sprocket manufacturing flaw imaging technology.