Wednesday, November 12, 2014

Synthetic diamond market leader provides tool manufacturers the ability to develop next-generation 3D composite tooling solutions

ADVANCED ENGINEERING SHOW 2014, Birmingham, United Kingdom - November 12, 2014 – Element Six, the world leader in synthetic diamond supermaterials and member of the De Beers Group of Companies, today announced the launch of its new Polycrystalline Diamond (PCD) product portfolio Aero-DianamicsTM, proven to achieve a 3 times improvement in productivity and reduced cost per finished part, in the processing of composite materials, including carbon fibre reinforced plastics (CFRP), compared to today’s tungsten carbide tooling systems. 

Aero-DianamicsTM performance advantages have been validated in independent tests by two of Europe’s leading Aerospace precision machining research institutions, the Advanced Manufacturing Research Centre (AMRC) in partnership with Boeing, at the University of Sheffield, United Kingdom and the Institute of Production Management and Technology (IPMT) at Hamburg University of Technology (TUHH), Germany. “Our testing to date has shown Element Six’s Aero-DianamicsTM range significantly outperforms tungsten carbide, and has the potential to support the global aerospace industry’s adoption of CFRP.” said Professor Keith Ridgway CBE, Director and joint founder of the AMRC with Boeing.

For the first time, the Aero-DianamicsTM range allows a three-dimensional (3D) cutting geometry to be achieved, in a PCD mill or drill, representing a revolutionary step change in tool design.  The Aero-DianamicsTM product portfolio consists of five production-ready PCD round tool blanks, which when built into tooling systems, increase the ability of manufacturers to mill and drill CFRP faster, more cleanly, at lower temperatures and with lower tool forces. Consequently, CFRP airframe components can be produced more efficiently and rapidly, decreasing lead-times for the delivery of finished components for assembly.

“Element Six’s Aero-DianamicsTM PCD components allowed SECO Tools to develop the industry’s first PCD three-flute helical geometry drill for composite drilling – CX1”, said Par Nordberg, Product Manager – Drilling at SECO Tools, a leading manufacturer of high performance metal cutting tools and long-time customer and partner of Element Six. “This revolutionary drilling tool enables new level of productivity and tool life, simply not possible with traditional PCD”, added David Pearson Business Development Manager – Aerospace, at SECO Tools.

Element Six is at the forefront of developing multi-dimensional PCD tool solutions, built on its unrivalled experience acquired over 50 years. “We are excited to add the Aero-DianamicsTMrange to our already extensive synthetic diamond capabilities, which extends to the machining and grinding of virtually all complex materials found in the main components of modern aircraft,” said Tom Howard, Head of Product Management Precision Machining at Element Six. “As other industries increasingly see the adoption of composite materials, such as automotive and turbine processing, over the course of the next 3 to 5 years, we predict that they will also benefit from this new portfolio”.

If you are interested in learning more about Element Six’s Aero-DianamicsTM range, please visit

Press interested in speaking with an Element Six spokesperson can contact

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