Custom carbide manufacturing

Your custom carbide part in 10 steps

We manufacture custom carbide parts from a batch size of 1 – with
extremely short delivery times, all year round and regardless of capacity peaks.

In Odelzhausen, centrally located between Munich and Augsburg, we combine all manufacturing steps under one roof: from powder preparation, pressing and sintering to finishing by grinding, EDM, lapping, honing and more.

The result is custom carbide solutions that perform reliably even with complex geometries and tight tolerances – from the first tungsten carbide powder to the ready-to-use precision part.

Step 1 – Consulting

Design consulting for custom carbide parts – precision and cost-efficiency from the start

The development of a carbide precision part does not begin in production, but in design. This is exactly where unnecessary costs often arise: geometries that can only be produced with extensive grinding, tolerances without any technical benefit, or a carbide grade that does not match the required tool life.

Our design consulting for custom carbide parts addresses precisely this. We review drawings and concepts in terms of manufacturing efficiency, material usage and process reliability. We show which contours can already be pre-profiled cost-effectively in the green compact, where tolerances should be adjusted and which carbide grade offers the best properties for your application.

Your advantage:
A design that is optimized for carbide from the very beginning – saving time, costs and subsequent changes.

Step 2 – Formulation

In-house carbide grades and powder preparation

Quality begins with the powder:

Instead of relying on standard mixtures, we develop and mix our carbide grades ourselves – based on precisely defined formulations. We use tungsten carbide, cobalt, nickel and mixed carbides such as WCTaC. Each composition is tailored specifically to our customers' requirements: from maximum wear resistance to optimum toughness under changing loads.

In our in-house laboratory, we test every batch for density, grain size distribution, hardness, porosity and more. Only when the values exactly match our specifications is the batch released for further production. This ensures that the later blanks not only correspond to the expected shrinkage, but also meet the highest standards in terms of hardness, tool life and dimensional accuracy.

With this in-house powder preparation, we control the entire process from the very beginning. This allows us to adjust material properties in a targeted way – for example the expected wear behavior or other demands the tool will face in its final application. This is what distinguishes standard products from genuine custom carbide parts developed for the most demanding applications.

Step 3 – Pressing technology

Pressing technology and pre-profiling – the foundation of precision

To turn powder into a resilient carbide blank, we use state-of-the-art pressing methods. Depending on the part geometry, we work with axial pressing or cold isostatic pressing (CIP). We manufacture the required tools individually – precisely matched to the respective contour.

The goal is a near-net-shape preform that comes as close as possible to the final geometry while still in the so-called green state. This pre-profiling makes the decisive difference: the more precisely the green compact is pressed, the less grinding is needed later. This not only saves material and time in finishing, but also increases process reliability.

Complex details can already be added at this stage:
holes, cooling channels or threads can be integrated directly into the green compact – without costly machining after sintering.

This approach produces blanks with high dimensional accuracy and reproducible quality.

What this means for our customers: less grinding, shorter lead times and stable repeatability – measurable advantages in production.

Step 4 – Isostatic pressing

Isostatic pressing – homogeneous carbide blanks in custom shapes

When geometries become more complex or particularly high density is required, we use isostatic pressing (CIP – cold isostatic pressing). In this process, the ready-to-press carbide powder is placed in flexible molds and then compacted with uniform pressure from all sides – up to 2,500 bar.

The advantage: the pressure does not act on individual points, but evenly on the entire part. This produces homogeneous carbide blanks with particularly dense, uniform pre-compaction and minimal internal stresses in the green state. This is exactly what matters when dimensional accuracy after sintering is critical.

The process is ideal for cylindrical, rectangular or freely defined custom shapes that require only minor finishing later on. Even with complicated geometries, reproducibility remains consistently high – a clear advantage over purely axial pressing.

Combined with our axial pressing process and in-house toolmaking, we respond flexibly to any drawing – from batch sizes of 1,000 to larger series of more than 20,000. This creates the basis for cost-efficient manufacturing processes and reliable carbide parts that withstand even extreme conditions.

Step 5 – Machining

Green machining – efficiency and precision from a quantity of 1

A decisive advantage in carbide manufacturing is machining in the green state. Before the part is sintered, we machine the blanks by turning, milling and grinding – precisely matched to the subsequent shrinkage, which must be determined exactly beforehand.

Why is this so important? Machining in the green state requires considerably less force than machining sintered carbide. This makes even complex geometries, holes or thread preparations possible in a cost-effective, near-net-shape way. At the same time, material consumption decreases because unnecessary removal in the sintered final state is avoided.

This strategy not only saves time and costs in the finishing of carbide parts, but also increases dimensional accuracy and repeatability. We can produce precise custom parts from a quantity of just 1 – with tight tolerances that are reliably maintained.

Green machining thus becomes the key to greater efficiency across the entire process chain: less grinding, shorter lead times and production designed for cost-efficiency from the outset.

Step 6 – Sinter-HIP process

Sinter-HIP – maximum density and strength for carbide parts

After green machining comes one of the most crucial steps in carbide manufacturing: the sinter-HIP process. Here we combine conventional high-temperature sintering with isostatic gas pressure treatment. At temperatures above 1,400 °C and with uniform gas pressure, the part is densified and acquires its final material properties.

The result is a homogeneous microstructure with maximum density, dimensional accuracy and wear resistance. Even complex custom geometries or small series can be produced reliably – without internal stresses that could later lead to distortion or dimensional deviations.

An important factor is the shrinkage of around 25 % that occurs during sintering. This effect is already precisely factored into pre-profiling and green machining. As a result, the finished carbide part matches the drawing exactly – even with tight tolerances.

The combination of sinter-HIP, process control and experience produces carbide blanks that withstand extreme mechanical loads while forming the basis for cost-efficient finishing.

Step 7 – Grinding technology

Carbide grinding – precise finishing with diamond tools

Grinding is one of the central steps in carbide manufacturing. Only finishing gives a part its final dimensional accuracy, surface quality and precise fit. For this, we rely on a modern machine park and work exclusively with diamond grinding wheels – the only material that can reliably machine carbide. The result is precision parts down to the micrometer range that meet the highest requirements.

Our range of services includes:

• CNC external and internal grinding for rotationally symmetrical parts
• Surface grinding and centerless grinding for precise flatness and concentricity requirements
• 5-axis CNC grinding for complex custom geometries with maximum flexibility
• Polishing and finishing for perfect surfaces as per drawing
• Wire EDM for complex contours
• Sinker EDM for cavities or special requirements
• Lapping for very cost-efficient surface finishing
• Joining processes such as shrink fitting, brazing or bonding

Combining these processes produces dimensionally accurate carbide parts that can be manufactured cost-effectively and reproduced with high repeatability – with the tightest tolerances and surface qualities that make the difference.

Step 8 – Joining carbide

Joining carbide and steel – brazing, shrink fitting, bonding

Not every part is made of solid carbide. In many applications, it is more economical and functional to combine carbide inserts with steel bodies or other materials. This creates assemblies that combine the hardness and wear resistance of carbide with the stability and flexibility of steel.

For these connections, we rely on proven joining processes:

• Brazing – for permanently strong joints even under high mechanical and thermal loads
• Shrink fitting – joining steel parts with carbide at lower temperatures than brazing
• Bonding – for applications that require flexibility, temperature resistance or vibration-damping properties

We adapt these processes precisely to the respective application, load and operating environment. Thanks to decades of experience, we ensure that the joint not only holds, but also performs reliably in later use.

The result is hybrid assemblies that optimally combine functionality and cost-efficiency – and are then precisely finished to final dimensions in our fine machining department.

Step 9 – EDM, lapping & honing

EDM, lapping and honing of carbide – for perfect contours, surfaces and bores

The final machining of custom carbide parts is all about maximum precision. With EDM, lapping and honing, we use three specialized processes to produce contours, surfaces and bores exactly as per drawing.

EDM of carbide
Whether wire EDM or sinker EDM – both processes enable complex internal contours, undercuts and openings in carbide. They work with high form accuracy, without stress and without mechanical load on the workpiece. This makes even delicate structures and deep geometries possible – ideal for small series and custom parts from a quantity of 1.

Lapping and honing
Lapping produces extremely fine surfaces with high plane parallelism, which is particularly important for functional and sealing surfaces. Honing, in turn, gives bores and fits perfect roundness and improves cylindricity – important for parts that will later be subjected to dynamic loads.

Combining these processes produces carbide parts with maximum dimensional accuracy, surface quality and repeatability – designed for applications where absolute reliability is essential.

Step 10 – Quality assurance

Quality assurance & metrology – documented precision in carbide manufacturing

Precision must not only be achieved, but also proven. That is why quality assurance is an integral part of our carbide manufacturing.

All custom carbide parts are inspected and measured in-house – with a complete measurement report on request. We use tactile coordinate measuring machines that reliably capture geometric dimensions down to the micrometer range, as well as high-resolution optical systems that deliver precise results, especially for complex geometries and sensitive surfaces. Both methods are regularly calibrated and documented in accordance with current standards, so that measurement results are traceable at all times.

In addition, our in-house powder metallurgy laboratory analyzes every batch for its physical properties. These include hardness, density and grain size, supplemented by microscopic structural analyses to ensure material homogeneity and quality over the long term. Only when all values are within the target range are the parts released for further processing or delivery.

Quality assurance therefore does not end at a single point, but accompanies the entire manufacturing process – from the powder and the green compact to the finished, ground precision part. This creates a complete inspection trail that ensures both internal process reliability and external traceability.

This gives our customers the certainty that precision, dimensional accuracy and reliability are fully documented and permanently assured in every batch.