HOW TO PROCESS

Application Process

In the Mold & Die manufacturing industry, Crownkyn provides diamond- and CBN-based superhard material solutions for cutting, grinding, lapping, polishing, and surface finishing of high-hardness tooling materials. Product selection and grit sizing are matched to mold material chemistry, hardness, and thermal load, helping you achieve stable processing, predictable tool life, and consistent quality in precision mold production.

Cutting and Pre-Machining

Cutting and pre-machining of mold materials require superhard abrasives precisely matched to the workpiece chemistry to control tool wear and thermal damage.

Hardened steels & cast irons: Monocrystalline CBN Powder for chemical stability and high-temperature cutting performance
Cemented carbides: Monocrystalline CBN Powder for stable, economical cutting; Ti/Ni-coated diamond powder used to fabricate precision cutting tools for well-cooled finishing
Non-ferrous molds (aluminum, copper alloys): Saw grit monocrystalline diamond for maximum cutting efficiency and clean edges

Typical applications: Hardened steel mold bases, cemented carbide inserts, aluminum injection molds, copper alloy mold cores.

Precision Grinding and Shaping

Precision grinding and shaping are critical for achieving tight tolerances and stable geometry in mold manufacturing. Material-specific abrasive selection is essential to ensure grinding stability and surface integrity.

Carbide, ceramics, non-metallics: Wheel grit monocrystalline diamond for stable wear; crushed diamond in resin-bond wheels for aggressive cavity roughing with high initial cutting
Hardened steels & high-speed steels: Monocrystalline CBN for thermal stability; coated CBN for high-load deep grinding and longer wheel life

Typical applications: Injection molds, precision connector stamping dies, extrusion dies, forming tools.

Lapping and Polishing

Lapping and polishing aim to achieve low roughness, high flatness, and defect-free mold surfaces. Micron diamond powder, micron CBN powder, diamond slurry, and paste provide controlled and repeatable surface refinement. The selection between diamond and CBN micron abrasives follows the same material compatibility principles as grinding. Micron CBN powder is especially suitable for hardened steel molds, offering higher wear resistance than conventional abrasives.

Pre-lapping: 15–30 μm for surface correction and flatness control
Fine lapping: 6–14 μm to remove grinding marks
Final polishing: 1–3 μm or finer for high-precision mold surfaces

Typical applications: Mobile phone camera lens molds, automotive optical molds, precision stamping dies, glass forming molds.

Ultra-Fine Finishing and Surface Engineering

For high-end molds requiring mirror finishes and extended service life, ultra-fine finishing and thermal management materials are essential. Nano Diamond Powder supports mirror-level surface generation, while Thermal Conductive Diamond is applied in molds exposed to severe thermal cycling.

Ultra-fine finishing: ≤1 μm and nano-scale diamond for mirror-finish mold surfaces
Surface durability enhancement: Diamond micro-powder to improve wear resistance
Thermal management: Thermal conductive diamond to reduce cycle time, warpage, and heat checking in molds

Typical applications: High-gloss injection molds, optical lens molds, new-energy vehicle motor housing die-casting molds, high-cycle precision tooling.

Mold & Die Manufacturing Application Overview

Manufacturing Area	Key Materials	Crownkyn Product Solutions	Value to You
Pre-Machining & Cutting	Hardened steel / Carbide	Monocrystalline CBN Powder, Coated Diamond (for PCD tools)	Reduce cutting tool wear by 20–30% and eliminate thermal damage risks
Precision Grinding	Carbide molds / Steel dies	Diamond & Crushed Diamond (for carbide) / CBN & Coated CBN (for steel)	Achieve form tolerances below 5 μm with significantly longer wheel life
Lapping & Polishing	Precision mold surfaces	Micron diamond or micron CBN slurry and paste	Deliver low roughness and high flatness for precision mold surfaces
Ultra-Fine Finishing	High-end molds	Nano diamond, thermal conductive diamond	Deliver mirror finishes and reduce mold cycle time in high-cycle production

Crownkyn supports mold and die manufacturers with application-driven diamond and CBN materials, helping you reduce process variation, extend tool life, and ensure reliable quality in high-precision industrial tooling production.