Ultra-Sonic Assisted Diamond Tools

Single Crystal Diamond (SCD/MCD) Inserts for Ultra-Precision Machining

Achieve the ultimate in surface finish and dimensional accuracy with custom-manufactured Single Crystal Diamond (SCD/MCD) Inserts. Representing the pinnacle of cutting-edge technology, these inserts are the premier choice for applications demanding mirror-like surfaces (Ra ≤ 0.1 µm) and sub-micron tolerances, particularly when machining non-ferrous metals and polymers.

The Pinnacle of Cutting-Edge Technology: Single Crystal Diamond

Single Crystal Diamond—also known as Monocrystalline Diamond—is a synthetically grown, flawless diamond structure that offers unique machining advantages:

• ·  Atomically Sharp Cutting Edge: Can be ground to an exceptionally sharp, defect-free edge (with a potentially nanometer-scale radius), enabling material removal with minimal force and deformation.

• ·  Unsurpassed Surface Finish: Produces mirror-like surfaces (Ra ≤ 0.1 µm) directly from the machining process on compatible materials, often eliminating the need for polishing or lapping.

• ·  Ultimate Hardness & Wear Resistance: Provides outstanding abrasion resistance when used on suitable materials, ensuring long tool life under controlled cutting conditions.

• ·  Material Compatibility: Excels in machining most non-ferrous metals (including aluminum & alloys, copper & alloys, oxygen-free copper, gold, silver, brass, and bronze), polymers (such as Acrylic/PMMA and Polycarbonate), and certain soft composite materials.
  (Note: SCD is generally unsuitable for machining ferrous metals due to high chemical affinity, or for very hard ceramics due to its relative brittleness.)

• ·  Important Considerations: While extremely hard, SCD is more brittle than PCD or cemented carbide. Successful application requires high-precision, dynamically stable machine tools, minimal vibration, and carefully optimized cutting parameters.

Customized Insert Geometry — Tailored to Your Exact Needs

We specialize in manufacturing SCD inserts with precisely controlled geometries customized to your specific application and toolholder design. Based on your detailed drawings, we can produce diamond inserts featuring:

• ·  Micro-Precision Dimensions & Tolerances: Exceptional accuracy on critical features—such as width (e.g., 3.92 ± 0.2 mm), cutting-edge arc radius (customized per requirement), center height (e.g., 3.34 ± 0.02 mm), and body thickness (e.g., 2.38 mm)—demonstrating our advanced micro-machining capability.

• ·  Diamond Type Options: Natural Diamond or Synthetic Diamond (MCD/SCD).
  

• ·  Tool Holder Configuration: Insert-type design, compatible with standard or custom alloy shanks.

• ·  Controlled Crystallographic Orientation: The diamond crystal structure can be oriented relative to the cutting edge to maximize wear resistance and maintain edge integrity for specific cutting directions.

Primary Application Areas for SCD Inserts

SCD inserts deliver superior results in industries where ultimate precision and surface quality are essential:

• ·  Optical Industry: Machining molds and inserts for plastic lenses, light guides, Fresnel lenses, and reflectors; direct machining of optical crystals or polymers.

• ·  Ultra-Precision Molds & Dies: Producing mirror-finish cavity surfaces for high-clarity plastic injection molding or reflective component forming.

• ·  3C Electronics Manufacturing: Creating high-gloss “diamond-cut” finishes on metal (e.g., aluminum, magnesium alloys) or plastic housings and components for smartphones, laptops, and other electronics.

• ·  Acrylic / Polymer Processing: Generating optically clear, smooth surfaces on PMMA and other plastics for displays, light panels, decorative items, and medical applications.

• ·  Medical Device Industry: Precision machining of non-ferrous metal or polymer components requiring exceptional accuracy, fine finish, and biocompatibility.

• ·  Jewelry & Watchmaking: Producing high-luster, flawless finishes on precious metals such as gold, silver, and platinum.

Collaborative Development & Manufacturing

• ·  Your Input Is Key: To develop the perfect SCD insert, we rely on your detailed drawings, application data (work material, machining operation, desired surface finish Ra / tolerance), and, ideally, your intended processing parameters.

• ·  Our Expertise: Using this information, our engineers craft custom SCD inserts of outstanding quality and precision—perfectly tailored to your machining requirements and designed for seamless integration into your specific toolholders or cutting bodies (e.g., turning tools, milling cutters, boring bars).

Contact our ultra-precision machining specialists today to discuss your requirements and discover what’s possible with custom Single Crystal Diamond inserts.