Wear Protection Solutions for Tool Making
In tool making, every hundredth of a millimetre counts. Punches, dies, cutting and blanking knives operate under high pressure and constant friction, and even the smallest deviations at a cutting edge or forming surface show up immediately in the produced part.
With increasing production runs, cutting edges wear down, forming surfaces lose their dimension and contours become imprecise. A new tool is expensive and barely replaceable at short notice in series production.
We supply wear protection solutions, spare parts and welding consumables that address exactly these issues and keep your components in service longer.
Typical Welding Defects on Punches, Dies and Cutting Tools
When repair welding precision tools, the welding consumable and parameters determine dimensional accuracy and edge stability. Two defect patterns occur particularly frequently — both can be reliably avoided with the right approach.
Problem: Cracking Due to Excessive Heat Input
An unsuitable alloy or excessive heat input leads to cracks in the applied layer. On delicate blanking and cutting knives, this renders the tool unusable instead of extending its life.
Our Solution: Controlled Welding Parameters and Suitable Consumable
With preheating, a matched layer sequence and slow cooling, we keep thermal stresses low. An edge-stable, crack-free welding consumable secures the cutting edge.
Problem: Dimensional Deviations and Incorrect Radii
Even a small dimensional deviation or an incorrectly executed radius on dies and injection moulding tools impairs component quality in series production. The tool then no longer fulfils its function.
Our Solution: Precise Reworking and Dimensional Control
After overlay welding, we bring functional surfaces to exact nominal dimension by milling, grinding or EDM. Dimensional control, templates and 3D scanning verify geometry and radii.
Suitable Welding Consumables for Punches, Dies and Cutting Knives
In tool making, one thing matters above all: the applied layer must be homogeneous, crack-free and edge-stable. Cutting edges must remain sharp, forming surfaces dimensionally accurate and contours exact. We select the filler material according to base material, tool type and load. On highly stressed cutting edges and forming surfaces, edge-stable hard overlay layers are used, matched to blanking, forming or injection moulding loads. This keeps functional surfaces dimensionally accurate over long production runs. Via the following wear types you can reach the appropriate welding consumables for each application area.
Corrosion
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Metal-to-metal friction wear
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Impact stress
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Temperature
Show productsSpare and Wear Parts for Tool Making
In tool making, tools such as punches and dies, cutting and blanking knives, bending and forming inserts, calibration inserts, and guide strips and ejectors are subject to particularly heavy wear. We rebuild them with targeted hard overlay and restore them. Here you will find suitable wear and spare parts for your equipment:
Fully Automated Overlay Welding and Additive Manufacturing
In the Laser Competence Centre, capilla brings together modern technologies for coating and component manufacturing.
Here, components are specifically treated, wear-resistant layers are applied and complex components are manufactured using additive processes such as 3D cladding.
This enables solutions that go beyond conventional welding applications and make components sustainably more capable.
Andreas Frische
Technical Management
Do you have wear problems, recurring damage or want to operate your plant more economically?
Our experts support you in selecting suitable welding consumables, in treating components and in developing long-lasting solutions.
Together we will find the approach that fits your application both technically and economically.
+49 5202 97790-54
Available from 07:45 - 16:30
a.frische@capilla-gmbh.de
Available from 07:45 - 16:30
Why capilla
Holistic Approach
From welding consumable to finished component – all solutions work together.
Focus on Wear
Specialisation in applications with high abrasion and mechanical load.
Practice-Oriented Consultation
Analysis of real applications rather than theoretical recommendations.
Proprietary Technologies
Laser Competence Centre for coating and additive manufacturing.
capilla Wear Protection to Bulk Material Specification
We do not work with standard recipes. Whether bulk material, medium or workpiece — what matters is always the actual load acting on the component. Grain size, hardness, temperature, flow or chemical aggressiveness determine which type of wear dominates and which protection truly fits.
Before we define the welding consumable, process and layer structure, we analyse the operating conditions. This results in a solution tailored to your component. Tested consumables and defined parameters are part of this — supplemented by standards-compliant documentation for safety-critical components.
Frequently Asked Questions about Wear Protection in Tool Making
In tool making, there are high demands on precision and wear resistance. Welding consumables must produce homogeneous, crack-free and edge-stable applied layers that keep punches, dies, cutting and blanking knives, and forming and calibration inserts dimensionally accurate and functionally reliable. Only this ensures tool service life and tool durability at high production volumes in blanking technology and forming technology.
The greatest tool wear occurs at functional surfaces: at cutting edges of cutting and blanking knives, at forming surfaces of punches and dies, at edges of calibration inserts and at contact zones of forming inserts. Added to this is tool surface wear on blanking and bending tools as well as on injection moulding tools, where friction and pressure act continuously.
Punches, dies, cutting tools and cutting knives are protected by targeted hard overlay layers. The layer is applied precisely where tool surface wear acts most strongly, and then precisely reworked. This keeps functional surfaces and edges of blanking, cutting and bending tools dimensionally accurate over long production runs.
In tool making, homogeneous, crack-free and edge-stable alloys are used. They are designed so that cutting edges on blanking and cutting knives remain sharp, forming surfaces on punches and dies remain dimensionally accurate, and forming inserts permanently retain their geometry. Material selection is based on base material, tool type and load in the specific production process.
Critical are cracking, incorrectly executed radii and significant dimensional deviations. On blanking knives, dies and injection moulding tools, even a small deviation is enough to impair component quality in series production. An unsuitable welding consumable or excessive heat input can also actually intensify subsequent tool wear.
Cracking and dimensional deviations are avoided through controlled welding parameters. Preheating, a matched layer sequence and slow cooling reduce thermal stresses; a suitable welding consumable ensures edge stability. Especially for delicate blanking knives or cutting knives, parameter management determines tool service life after repair.
Forging tools are restored by precise repair welding at the worn functional surfaces. Material is applied specifically, then reworked to nominal dimension by milling, grinding or EDM. This allows punches, dies, cutting, blanking and bending tools to be rebuilt multiple times instead of being replaced, significantly extending tool service life.
Hard overlay brings longer service life and consistent quality in series production for blanking tools, forming tools and injection moulding tools. Tool wear is shifted to the specifically protected zones; the tool surface remains dimensionally accurate for longer. This reduces downtime, regrinding intervals and tool costs per produced part.
Quality is assured through dimensional control and visual inspection, supplemented by templates and 3D scanning. This allows the geometry and dimensional accuracy of punches, dies, calibration inserts and injection moulding tools to be reliably verified after repair welding. Especially for complex contours, 3D scanning is often the only way to fully inspect all functional surfaces.
Quality remains stable through reproducible processes — meaning documented welding parameters, controlled heat management, qualified welders and defined inspections for each tool. This allows tool service life and dimensional accuracy of blanking, forming and injection moulding tools to be maintained at a consistently high level over many repair cycles.