Additive Manufacturing and Smart Sensors: The Future of Carbide Tooling

The world of carbide tooling is changing fast. As manufacturers face higher expectations for precision, throughput, and cost control, new technologies are reshaping what’s possible. 

In 2026, additive manufacturing (AM) is moving from the lab to the production floor. Binder-jet and laser-based processes now make it possible to create complex tungsten-carbide geometries with internal cooling features and lightweight lattice structures — impossible with traditional pressing and grinding. These innovations mean faster design cycles, custom inserts, and on-demand spare parts.

 

At the same time, smart tooling and embedded sensors are transforming production lines. By tracking temperature, vibration, and strain in real time, AI-driven systems can predict tool wear before it causes downtime, ensuring consistent part quality and extending tool life.

 

Raven Carbide Die is watching these trends closely — and applying emerging technology to help manufacturers improve precision and productivity. Learn more about what’s next in carbide tooling for 2026 here.

 

 

Start Implementing What’s Next in Carbide Tooling with Raven Carbide Die

Want to see how these innovations could benefit your operation? Contact us today to explore the next generation of carbide tooling.

Best Carbide Grades for Extrusion Dies: Hardness Matters

In extrusion applications, where material is continuously forced through a die opening, friction and heat are constant challenges. Hardness and wear resistance take priority over impact strength.

Fine-grain carbide grades (K05–K20) with lower cobalt content provide excellent performance in extrusion dies, maintaining sharp edges and surface quality even under intense thermal and abrasive conditions. For long production runs or highly abrasive materials, ultra-fine carbide grades offer even greater wear resistance, helping you maintain dimensional consistency and avoid costly die erosion.

 

While cold form dies require toughness to resist cracking and chipping, extrusion dies depend on hardness and wear stability to withstand continuous material flow. Understanding these distinctions is key to selecting the right carbide grade for your process.

 

We work with manufacturers to fine-tune carbide selection for each application—whether it’s cold form dies or extrusion tooling. From material choice to final finishing, our dies are designed to deliver precision, consistency, and longevity under the toughest manufacturing conditions.

 

Contact Raven Carbide Die today to discuss your tooling needs or request a quote. Our team can help you choose the best carbide grade for your cold forming or extrusion operation—ensuring maximum performance, durability, and value.

 

Choosing the Right Carbide Grade for Cold Form Dies

Cold forming is a process that subjects dies to tremendous stress through compression. For manufacturers, selecting the right carbide grade is key to preventing cracking, chipping, and premature wear.

Medium to coarse-grain carbide grades (typically in the K20–K40 range) with higher cobalt content are best suited for Cold Form Dies. These grades provide the toughness needed to withstand repeated impact while maintaining consistent performance and dimensional accuracy.

 

Submicron carbide grades are another excellent choice for smaller, high-precision parts where superior finish and tight tolerances are critical. By using the optimal carbide composition, you can significantly extend die life and reduce downtime, ensuring maximum productivity across production runs. Read more about choosing the right carbide grade for cold form dies in our latest article.

 

We specialize in matching carbide materials to your forming process. Our precision engineering ensures your dies deliver lasting performance under even the most demanding conditions. 

 

Contact Raven Carbide Die today to discuss your tooling needs or request a quote. Our experienced team can help you choose the best carbide grade for your cold forming or extrusion operation—ensuring maximum performance, durability, and value.

Avoiding Chipping and Cracking in Carbide Dies

While carbide dies are built to withstand high pressure and heavy use, they can fail when subjected to improper handling or extreme conditions. Two of the most damaging issues are chipping and cracking.

Chipping

 

Chipping occurs when small pieces of carbide break off the die surface, often caused by misalignment, excessive shock loads, or rough handling.

 

Prevention tips:

• Handle and store dies carefully.
• Ensure proper alignment in tooling.
• Avoid sudden impacts or loads beyond capacity. 

Cracking & Breakage

Cracks develop when a carbide die is exposed to severe stress, thermal shock, or improper installation. Once cracks form, the die becomes unsafe.

 

Prevention tips:

• Prevent sudden temperature changes.
• Install with proper fits and mounting techniques.
• Stay within recommended operating limits.

 

Proactive maintenance and correct handling practices can help avoid these costly failures. Learn more about common carbide die failures and how to avoid them here.

 

👉 Ensure durability and precision in every application—contact us today to learn about long-lasting carbide die solutions.

How to Prevent Wear in Your Carbide Dies

Carbide dies are known for their exceptional hardness and durability, but like any tool, they aren’t indestructible. One of the most common causes of carbide die failure is wear. Over time, constant contact with hard or abrasive materials gradually erodes the die’s working surface. This increases clearances, reduces precision, and leads to inconsistent product quality.

 

How to Prevent Wear in Carbide Dies

 

• Use proper lubrication to minimize friction and protect against surface damage.
• Match die grade to the application so the die can handle the hardness and abrasiveness of the material.
• Inspect regularly and recondition before wear becomes critical.

 

By identifying wear early and following these best practices, manufacturers can extend carbide die life and improve production efficiency. Learn more about common carbide die failures and how to avoid them here.

 

👉 Stop failures before they start—contact us today for custom carbide dies engineered to deliver long-lasting performance.

Carbide Die Blog Presents - Machinist Humor 2024!

 Welcome to the latest and greatest instalment of shop humor from the carbide dies blog. Humor has long stopped murders on the shop floors across our great planet... please find the latest selection and let us know of any we missed!

And you thought ChinA was bad... wait till you hear about this!

LOL... wait until they hear about tungsten carbide.

I'm not sure if this is more funny or true!

This impressive canyon is what a crack in steel looks like!

The guy we all worked with, if not, this is probably you.

Heading home from the shop on Friday for date night.

The allen wrench selection in the shops general tool box.

Thank you one and all! Be sure to check out the other instalments we have posted over the last 10 years if you can believe that!

 H.B. Carbide, a provider of carbide blanks and pre-forms, has been named 2023 Supplier of the Year by Raven Carbide Die, New Boston, Michigan. This is in recognition of H.B.’s customer service and consistent on-time delivery of high-quality pre-forms, which has played a significant role in Raven Carbide Die’s operations and success.

“This recognition means a lot to the entire H.B. Carbide team,” said Jon Wyniemko, H.B. Carbide global sales director. “It is truly rewarding to know that our efforts pay off in helping our customers achieve and exceed their goals.”

“H.B. Carbide’s role as a collaborating partner has been a key factor in enhancing our competitiveness and allowing us to manufacturer premium carbide dies and tooling, as well as helping us better serve our customers,” said Dan Raven, owner of Raven Carbide Die. “In light of this achievement, we look forward to further strengthening our partnership.”
H.B. Carbide has partnered with Raven Carbide Die since 2017, supplying the company with carbide die blanks used in the design and manufacture of cold forming dies, stamping dies and extrusion dies.

From Left to Right: Terry Raven (Owner), Jared Bielby, (Product Specialist) Dan Raven (Owner), Renee Raven.

RAVEN CARBIDE DIE (RCD)
RCD was founded in 2010 specializing in precision carbide dies for cold heading, cold forming and impact extruding applications. It offers dies made to any carbide grade and partners with customers to help in choosing a grade that provides the most efficiency for each application.  Its commitment to customers is to supply long-lasting dies and highly competitive rates.