Mold

New Technologies for Cutting Tools in the Mold Processing Industry (Latest Developments in 2025)

High precision composite machining technology
Five axis linkage micro milling: GF Archie Shamir’s μ milling cutter (diameter 0.01mm) from Switzerland achieves micro level mold detail machining with an accuracy of ± 1 μ m.
Ultrasonic vibration assisted cutting: DMG MORI’s ultrasonic tool holder (frequency 20kHz) reduces cutting force by 50%, making it suitable for processing hard and brittle materials such as ceramic molds.

Superhard materials and composite structure technology
Nanograin PCBN cutting tools: such as Sumitomo Electric’s BN-S20 series, optimized with nanoscale CBN grains (particle size 0.5 μ m) and cobalt based binders, can increase the service life by 50% when processing hardened steel (HRC60), and the cutting speed can reach 300m/min.
Gradient function PCD tool: Sandvik’s gradient PCD blade has a surface diamond content of 95% and a bottom layer containing a tungsten carbide transition layer, which improves impact resistance by 30% and is suitable for processing high silicon aluminum alloy mold cavities.

Intelligent cutting tools and sensing technology
Embedded sensor tool: Kennametal’s KSEM system integrates temperature and vibration sensors inside the tool holder to monitor cutting status in real-time. Through AI algorithms, parameters are dynamically adjusted to reduce chatter by up to 70%.
Self sensing coating technology: Fluorescent materials are embedded in DLC coatings to provide real-time feedback on wear status through spectral analysis, with an accuracy of ± 0.1 μ m.

Additive Manufacturing and Topology Optimization of Cutting Tools
3D printed hard alloy cutting tools: Sandvik Coromant’s 3D printed milling cutters adopt a lattice structure, reducing weight by 40% and increasing rigidity by 15%, making them suitable for deep cavity mold processing.
Biomimetic topology optimization: The biomimetic honeycomb structure tool body (such as OSG’s “honeycomb milling cutter”) reduces weight by 20% to improve acceleration and increase processing efficiency by 25%.

Advanced coatings and surface treatment
Super lubricating coating: The “DLC+MoS ₂” composite coating from Daido, Japan has a friction coefficient as low as 0.05, reducing cutting force by 40% when processing titanium alloys.
Laser micro texturing technology: Laser processing of micrometer sized pits (diameter 50 μ m) on the tool surface reduces chip adhesion and extends lifespan by 2 times.

Green cutting and cooling technology
Low temperature cold air cutting: -30 ℃ cold air replaces traditional coolant, reduces tool thermal stress, and ensures surface roughness Ra ≤ 0.4 μ m when machining aluminum alloys.
Electrostatic atomization cooling: High voltage static electricity atomizes the coolant into 5 μ m particles, directly reaching the cutting area and reducing the temperature by more than 200 ℃.

Digital twins and AI optimization
Virtual tool library: Siemens NX has a built-in digital twin model that can simulate tool wear under 100000 working conditions, optimizing parameters and increasing efficiency by 60%.
AI process recommendation: The “CAPTOR AI” system of Shangao Cutting Tools analyzes machining data through deep learning and automatically matches the best tool and parameter combination.