A long-term customer specializing in precision ceramic manufacturing approached us to produce three custom roller mold inserts for use in Ceramic Injection Molding (CIM) tooling.
These inserts are installed inside production molds used by a European manufacturer to emboss unique serial numbers onto ceramic green parts during the molding process. The marking enables full product traceability, helping the end customer comply with strict European quality and regulatory requirements for medical and electronic ceramic components.
The inserts were manufactured from ASP23 powder metallurgy high-speed steel, heat treated to 64–66 HRC to provide excellent wear resistance under continuous production conditions involving abrasive ceramic feedstock.
Customer Requirements
Although the components are relatively small, the manufacturing requirements were highly demanding.
The customer required:
· Dimensional tolerance of ±0.01 mm
· Profile tolerance within ±0.003 mm
· High-precision curved profiles (R0.85, R1.0 and R4)
· Mirror-polished contact surfaces to protect fragile ceramic green bodies
· Uniform 0.5 × 45° chamfers on all edges
· Consistent Wire EDM marking with controlled engraving depth
· Stable dimensional accuracy after heat treatment
Because these inserts directly influence both marking quality and mold service life, dimensional consistency was critical throughout production.
Engineering Challenges
The greatest challenge was not machining the geometry itself, but maintaining micron-level accuracy after hardening.
ASP23 reaches a hardness of 64–66 HRC after heat treatment, making subsequent finishing operations significantly more difficult. At this hardness, even slight deformation or grinding error can affect profile accuracy and the consistency of the embossed serial numbers.
In addition, the mirror-finished curved surfaces had to maintain their precise geometry while preventing scratches or damage to delicate ceramic green parts during molding.
Our Manufacturing Solution
To meet the customer's requirements, we developed a machining process focused on dimensional stability throughout every production stage.
The manufacturing process included:
· CNC machining of the pre-hardened blank
· Vacuum heat treatment
· Precision optical profile grinding of all critical curved features
· Wire EDM marking for traceability identification
· Mirror polishing of functional contact surfaces
· Final dimensional inspection before shipment
Critical curved profiles were finished using an AMADA GLS80PL Optical Profile Grinder, allowing precise control of complex radii while maintaining excellent surface quality on hardened ASP23 steel.
Inspection & Quality Control
Every insert underwent dimensional verification before delivery.
Inspection focused on:
· Critical dimensions
· Profile geometry
· Radius accuracy
· Surface finish
· Chamfer consistency
· Wire EDM marking quality
Inspection records were reviewed before shipment to ensure compliance with the customer's drawing requirements.
Results
The finished roller inserts met the specified dimensional and geometric tolerance requirements and were approved for production use.
The customer successfully integrated the components into their Ceramic Injection Molding process, supporting reliable serial number marking and stable production of precision ceramic parts.
Following this project, we have continued supplying customized mold inserts for similar applications.
Applications
These precision mold inserts are commonly used in:
· Ceramic Injection Molding (CIM)
· Medical ceramic components
· Semiconductor ceramic parts
· Electronic ceramics
· Industrial wear-resistant ceramics
· Precision tooling and mold manufacturing
Why Customers Choose Us
For projects involving hardened tool steels and micron-level tolerances, manufacturing experience is just as important as machine capability.
Our team supports customers with:
· Precision CNC machining
· Optical profile grinding
· Wire EDM
· Heat-treated tool steel machining
· Precision mold inserts
· Prototype and production manufacturing
· Inspection documentation upon request
Whether your project involves ASP23, SKH51, tungsten carbide, or other hardened tool materials, we can help evaluate your drawings and recommend a suitable machining solution.
FAQ
What is ASP23 steel?
ASP23 is a powder metallurgy high-speed steel known for its excellent wear resistance, toughness, and dimensional stability after heat treatment. It is widely used for precision tooling and mold components operating under high-wear conditions.
Why is optical profile grinding used for mold inserts?
Optical profile grinding provides extremely accurate control of complex curves, small radii, and geometric profiles that are difficult to achieve with conventional grinding methods. It is particularly suitable for hardened tool steels requiring micron-level accuracy.
What is Ceramic Injection Molding (CIM)?
Ceramic Injection Molding (CIM) is a manufacturing process used to produce complex ceramic components with high dimensional accuracy. It combines ceramic powders with binders, followed by injection molding, debinding, and sintering.
Can you machine hardened tool steel after heat treatment?
Yes. We machine various hardened tool steels, including ASP23 and similar materials, using precision grinding, Wire EDM, and other finishing processes to achieve tight dimensional and geometric tolerances.
Contact Us
Need custom precision mold inserts or high-hardness CNC machined components?
Send us your drawings, and our engineering team will review your project and recommend the most suitable manufacturing solution.
