In the manufacturing industry, efficiency, precision, and surface quality are essential for maintaining competitiveness and meeting modern production requirements. Among advanced cutting materials, Polycrystalline Diamond (PCD) has emerged as one of the most effective tool materials for machining non-ferrous and non-metallic materials. Due to PCD forming tools exceptional hardness, wear resistance, and thermal conductivity, PCD forming tools have become indispensable in the precision forming and machining of automotive, aerospace, electronics, and composite material components.

In the field of high-precision processing, PCD forming tools stand out for their outstanding performance, enabling the forming processing of various complex components and providing strong support for achieving high-precision and high-efficiency processing techniques.

PCD forming tools

PCD forming tools are cutting tools that use a Polycrystalline Diamond tip or insert for material removal or contouring operations. Unlike conventional tools, PCD tools are designed not only for simple cutting but also for profiling, shaping, or forming a specific geometry in a single pass. The forming geometry of the tool directly corresponds to the profile that will be produced on the workpiece.

Composition and Manufacturing

-A typical PCD forming tool consists of:

-Tool body: Usually made of carbide or steel, providing structural strength.

-PCD cutting edge: Brazed or sintered onto the tool body.

-Precision ground geometry: The PCD tip is laser-cut or EDM-shaped to match the required forming profile.

-The PCD layer thickness usually ranges from 0.3 mm to 1.0 mm, depending on the cutting depth and tool type.

FeatureS of PCD Forming Tools

-High hardness: The hardness value can reach 8000HV. Compared with carbide tools, it is 8 to 12 times harder. This characteristic enables the cutting edge of the tool to remain sharp for a long time, significantly reducing material wear, thereby effectively improving processing accuracy and surface quality.

-High compressive strength: When subjected to great pressure, it is not prone to deformation or cracking, providing a solid guarantee for the stability and reliability of the processing process.

-Good thermal conductivity: The thermal conductivity is as high as 700W/, which can quickly transfer the heat generated during the processing to the outside, effectively reducing thermal deformation and prolonging the service life of the tool, as well as improving production efficiency and reducing production costs.

-Outstanding wear resistance: During the processing, it can maintain the sharpness and integrity of the cutting edge for a long time, reducing the wear and dulling of the cutting edge, which enables the tool to maintain stable processing performance for a longer period of time without frequent replacement.

PCD forming tools are widely used in the processing of aluminum alloys for auto parts. The accuracy and smoothness of components such as the body, cylinder head, cylinder block, wheel hub, and engine piston all depend on PCD forming tools.

Applications of PCD Forming Tools

 Automotive Industry

In the automotive sector, lightweight and precision are two major design trends. PCD forming tools are widely used in machining aluminum alloy, copper, composite, and plastic parts.

Typical Components:

* Aluminum engine blocks and cylinder heads

* Transmission housings

* Brake systems

* Valve seats and valve guides

* Gearbox covers

* New energy vehicle components (motor housings, inverter plates)

Example:
When machining aluminum cylinder heads, PCD forming tools are used for precision contouring of valve seats or sealing surfaces. The result is a highly smooth surface with Ra < 0.1 μm, ensuring tight sealing and improved engine efficiency.

Aerospace Industry

The aerospace sector demands high precision and durability. PCD forming tools are ideal for machining composite materials (CFRP, GFRP) and aluminum-lithium alloys, which are difficult to machine with conventional tools.

Applications:

* Aircraft fuselage skin panels

* Turbine casing housings

* Composite structural components

* Aluminum brackets and fixtures

PCD forming tools prevent delamination and fiber pull-out when machining composites, extending tool life and improving surface integrity.

Electronics and Semiconductor Industry

In precision component manufacturing—such as optical lenses, smartphone frames, and semiconductor substrates—surface finish and dimensional accuracy are crucial. PCD forming tools are used to achieve micron-level precision and mirror-like surfaces.

Typical Uses:

* Aluminum and copper heat sinks

* Ceramic substrates

* Electronic connector housings

* Optical parts such as prism and lens molds

Their ability to maintain edge sharpness minimizes burr formation, ensuring clean edges and reduced post-processing.

Wood and Furniture Industry

For high-volume production of wood-based panels, MDF, and laminated materials, PCD forming tools provide unmatched wear resistance.

Applications:

* Edge banding and trimming

* Panel grooving and profiling

* Furniture component shaping

Compared to carbide tools, PCD tools last up to 20–100 times longer, reducing replacement costs and improving productivity.

Non-Metallic and Composite Materials

PCD forming tools are also applied in industries dealing with graphite, ceramics, carbon fiber, and reinforced plastics. These materials are extremely abrasive, quickly dulling conventional tools.

PCD forming tools maintain edge sharpness, ensuring dimensional stability and consistent surface quality throughout long runs.

The sharp edge of the PCD forming tool and the low processing friction coefficient can reduce sticking and chip accumulation, thereby achieving a smooth and free-of-bumps processing surface. Due to its strong wear resistance, the service life of PCD forming tools is also long. The high cutting speed of PCD forming tools not only improves production efficiency, but also effectively reduces thermal deformation during processing, improves the surface quality, reduces surface roughness, and is crucial for maintaining the accuracy and shape of the workpiece. During the processing, PCD forming tools maintain a stable geometric shape, are formed in one go, and ensure high precision, meeting the strict requirements of automotive parts for dimensions and tolerances, and ensuring the performance and safety of the final product.

The PCD forming tool, with its powerful material processing capabilities, can meet the processing requirements of complex parts in the aerospace industry. Aerospace parts are often highly complex in shape and have extremely high requirements for processing accuracy. The excellent cutting performance and processing accuracy of the PCD forming tool have made it one of the ideal tool choices in aerospace manufacturing and processing. The PCD forming tool can handle various composite materials (such as CFRP and GFRP) and fiber materials, effectively reducing phenomena like material tearing and delamination, ensuring that the processed components have a smooth surface without burrs, and meeting the most stringent quality requirements. Through non-standard design, the PCD forming tool can precisely meet these specific processing needs, not only improving the stability and precision of the processing process, but also extending the tool's service life and ensuring product consistency and interchangeability, thereby enhancing the overall quality of the product.

PCD forming tools are widely used in fields such as automobiles, aerospace, medicine, 3C, new energy, and watches. They play a crucial role in modern industry.