KYOCERA Hardcoating Technologies
KYOCERA Hardcoating Technologies
In the mold and die industry, surface durability isn’t a luxury, it’s a requirement. Whether forming ultra-high-strength steels or molding abrasive glass-filled polymers, tooling faces intense mechanical stress, thermal cycling, and material adhesion challenges. Failure at the surface leads to costly downtime, scrap parts, and premature tool replacement.
Physical Vapor Deposition (PVD) coatings are helping toolmakers and manufacturers meet these demands with confidence. These ultra-thin, high-performance coatings improve hardness, reduce friction, resist heat and wear, and extend tool life, all without changing geometry or disrupting fit.
In mold and die work, surface performance often determines tool longevity. That’s where PVD (Physical Vapor Deposition) makes its impact. Rather than adding thickness or changing tool geometry, PVD applies a precision coating just a few microns thick that drastically improves the surface without compromising tolerances.
The process takes place inside a vacuum chamber, where a solid source material such as titanium, aluminum, or chromium is vaporized and deposited onto the tool’s surface in a controlled, atom-by-atom build. The result is a hard, dense film that conforms exactly to the tool’s existing shape, even in tight corners, deep cavities, or ejector pins.
Two core methods are typically used:
Cathodic arc deposition, known for producing extremely hard and wear-resistant coatings.
Magnetron sputtering, which offers smoother finishes and better uniformity for intricate geometry.
The temperatures used during coating (typically 400–500°C) are low enough to prevent distortion of most tool steels but high enough to form a metallurgical bond between coating and substrate. This ensures excellent adhesion and long-term durability, even in the harshest forming or molding conditions.
Tooling used in molding and forming must perform under punishing conditions:
Stamping: High contact stress, edge wear, galling, and metal-to-metal pickup.
Injection molding: Thermal shock, abrasive filled materials, and release wear.
Die casting and hot forging: Extreme thermal cycling, erosion, and oxidation.
PVD coatings act as a shield at the surface. They protect core tool materials from wear and chemical attack, enhance performance, and extend the service interval between rework or replacement.
Kyocera offers several PVD coatings specifically designed to meet the demands of mold and die operations:
HTS Bronze (AlTiN/TiSiN bilayer) – Combines high hardness and thermal resistance. Ideal for hot forging, die casting, and high-speed metal forming.
HTC Rose (TiCN) – Excellent wear resistance with low friction. Ideal for injection molding of filled plastics or metal-forming where galling is a concern.
HTY Purple Black (AlTiN) – Strong oxidation and wear resistance for stamping dies and cold forming tools.
HTN Gold (TiN) – Multipurpose coating with improved lubricity and wear visibility. Useful in tooling requiring visual inspection or regrind tracking.
Each coating offers distinct advantages based on thermal loads, material interaction, and surface finish requirements.
PVD coatings can improve surface hardness to 3000+ HV, allowing tools to maintain sharpness and resist microchipping even under high load.
In progressive stamping dies, HTY coatings reduce edge wear and galling on high-strength steel.
In injection molding, HTC prevents abrasive wear from filled thermoplastics.
Coated dies maintain dimensional stability and reduce polishing needs over more production cycles.
Friction between mold and material contributes to sticking, drag marks, and surface defects. PVD coatings minimize this by lowering the coefficient of friction.
HTC TiCN improves plastic flow and reduces mold release agent requirements.
HTN TiN can improve surface finish and reduce polishing after EDM or grinding.
Fewer surface defects result in lower scrap rate and higher part yield.
In processes like die casting or hot forging, tools are exposed to temperatures exceeding 700°C. Standard tool steels can oxidize or soften.
HTS Bronze resists thermal softening and oxidation at high temperatures.
Maintains coating hardness even after repeated thermal cycling.
Protects die surfaces from soldering, erosion, and fatigue cracking.
Because PVD coatings are extremely thin and conformal, they’re ideal for tight-tolerance applications where post-coating rework is impractical.
No dimensional distortion or edge rounding.
Ideal for fine ribs, undercuts, and ejector pins.
Maintains tooling geometry for precision-critical parts.
Older surface treatments like hard chrome or salt bath nitriding pose environmental concerns and compliance headaches.
PVD coatings offer the following:
Environmentally friendly process with no hazardous waste or liquid byproducts.
No hexavalent chromium or cadmium.
REACH- and RoHS-compliant formulations.
Cleaner, safer working conditions for toolmakers and coaters.
| Component | Recommended Coating | Function |
|---|---|---|
| Progressive die punches | HTY AlTiN Purple Black | Galling resistance, long edge life |
| Plastic injection cavities | HTC TiCN Rose | Low friction, release improvement, cosmetic finish |
| Hot forging dies | HTS AlTiN/TiSiN Bronze | Thermal fatigue and oxidation resistance |
| Die cast inserts and cores | HTS Bronze | High-temp wear protection and anti-soldering |
| Ejector pins and core pins | HTN TiN Gold | Visual wear tracking, adhesion resistance |
| Fine-feature molds | HTC TiCN or HTN TiN | Friction reduction and precision protection |
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To get the most from your coating investment, your PVD provider should offer:
Application-specific guidance based on material, cycle count, and environment.
Thorough testing for hardness, friction, adhesion, and thermal stability.
In-house quality control and thickness verification.
Traceability for each batch and substrate type.
Support for tool trials, refinishing cycles, and maintenance best practices.
As customer expectations increase and production cycles grow more demanding, tool performance becomes a competitive differentiator. PVD coatings allow mold and die manufacturers to deliver longer-lasting tools, better part quality, and reduced downtime without changing materials or redesigning tooling.
From precision injection molds to large forming dies, the right coating helps tools last longer, run cleaner, and produce better results with fewer interruptions.
Explore our full lineup of coatings, or reach out to speak with one of our technical engineers. We’ll help you find the coating that’s right for your tool, your process, and your production goals.
Q: What is the best coating for extending the life of stamping dies?
A:Â For high-strength steel and abrasive materials, AlTiN- or TiSiN-based coatings like HTY or HTS are typically the best. They offer superior edge retention, heat resistance, and protection against galling and adhesive wear. Tool geometry and material should also be considered when selecting a coating.
Q: Can PVD coatings be applied to used or refurbished dies?
A:Â Yes. As long as the die is properly cleaned, polished, and free from surface damage or fatigue cracks, it can be recoated. Many shops recoat dies after regrinding to restore wear resistance and reduce costs.
Q:Â How thick is a typical PVD coating, and does it affect part tolerances?
A: PVD coatings are usually between 1–5 microns thick and are highly conformal. They do not significantly affect dimensional tolerances, which makes them ideal for precision molds and dies with tight clearances or intricate features.
Q: Do PVD coatings help reduce downtime in molding and stamping operations?
A:Â Absolutely. PVD coatings reduce wear, galling, and thermal damage, which leads to fewer tool replacements and polishing cycles. Many shops report extended maintenance intervals and improved part consistency after switching to coated tools.
Q: Can PVD coatings improve the surface finish of injection molded parts?
A: Yes. Low-friction coatings like TiCN can reduce drag and material buildup, improving flow and release. This results in smoother part surfaces, especially with filled or abrasive plastics.
Q:Â What are some cost-effective ways to improve die performance without redesigning the tool?
A:Â One practical way to enhance die performance without changing the tool design is to apply a PVD coating. Branded coatings such as HTY Purple Black (AlTiN) or HTC Rose (TiCN) can increase surface hardness, reduce friction, and extend tool life. This approach is commonly used on both new and refurbished tooling to reduce wear and improve part consistency with minimal cost or disruption to production.
Q: How can shops improve forming tool durability without investing in new tooling?
A:Â Applying a PVD coating to existing tools is a widely used strategy to boost durability and reduce wear. It allows manufacturers to get more life out of current dies by improving resistance to abrasion, galling, and thermal fatigue, especially in high-volume or high-friction applications.
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UNITED STATES
KYOCERA Hardcoating Technologies
220 Marc Drive
Cuyahoga Falls, Ohio 44223
USA
UNITED KINGDOM
KYOCERA Hardcoating Technologies – Europe
11 Ashville Way, Wokingham,
Berkshire RG41 2PL
United Kingdom
