Thermal debinding is one of the crucial steps in powder injection processing. To systematically analyze and design the thermal debinding step, a master decomposition curve (MDC) has been formulated and constructed based on the intrinsic kinetics of polymer pyrolysis. The Kissinger method is used to estimate the activation energy from thermogravimetric analysis (TGA) experiments. Overall thermal decomposition has been synthesized from the MDC's of individual components of the binder system with good experimental agreement. This can help process designers to change the composition without additional experiments and can help in predicting the remaining amount of each binder component during debinding. The input data are obtained from the industrial debinding practice. In addition, the catalytic or high conduction heat transfer effect of metal powders has been investigated in terms of different powders, shapes, and sizes.