Punches, Dies & Tool Sets

Powder compaction tooling is engineered to deliver consistent, high-quality performance in demanding press and sinter environments. Designed for use with ferrous and non-ferrous metal powders, technical ceramics, battery materials, tungsten carbide, and rare-earth magnet compounds, powder compaction tools support a wide range of industries including automotive, electronics, energy storage, and defense.

Hyperion offers standard powder compaction tooling, as well as solutions compatible with major quick-change systems including System 3R®, Erowa®, and ProGrit® to enable rapid changeovers and improved press uptime.

Hyperion combines decades of tool design expertise with vertically integrated manufacturing capabilities to ensure fast lead times, tight tolerances, and long tool life.

Powder compaction tooling is manufactured to exacting tolerances using advanced materials such as tungsten carbide, tool steels, and appropriate coatings. Tooling is available for single-axial, single-level, and multi-level designs to support complex part geometries in high-volume production. Application engineers can create original tooling designs or reverse engineer manufactured components for improvements.

Hyperion’s manufacturing plant in Pennsylvania, USA has machining capabilities to design and produce customized powder compaction tooling with features that include:

• Trapezoidal Cavities
• Broaching Tooling
• Swoop Dies
• Battery Tooling Dies
• Mirror-like surface finishes on internal cavities and punches

Complex tooling designs are created by in-house engineers using CAD/CAM. Designs become finished tooling through manufacturing capabilities like vapor polishing, multi-jet fusion, and metal binder jetting.

High-quality powder compaction tooling is essential to meet the increasing demand for high-performance permanent magnets manufactured in North America and Europe. Magnet powder compaction tools require complex geometries and compatibility with multi-level press hardware to reduce setup time.

Hyperion’s powder compaction tooling improves operational efficiency for permanent magnet manufacturers in three key areas:

• Minimized Quality Inspections: Hyperion performs quality inspections at multiple stages of tool production, not just before shipment. Carbide powder is processed with tightly controlled manufacturing specifications at Hyperion facilities in Michigan, USA, increasing tool quality at the earliest production stage. Tools are visually and dimensionally inspected, so tool sets meet quality expectations upon arrival at your plant.
• Decreased Out of Spec Parts: Tight-tolerances and mirror-like surface finishes enable tooling that minimizes the risk of cracking, sticking, and galling during production.
• Minimized Tool Spend: Tool sets are designed in carbide grades best suited to resist wear and corrosion over millions of cycles. Extended tool life starts with precision materials, but maintenance services further the usable life of powder compaction tooling. Hyperion offers retipping and refinishing services to bring tools to like-new condition to improve long-term tooling costs without sacrificing quality.

Tooling for Technical Ceramic Production

Technical ceramic tooling is engineered to deliver high dimensional accuracy and repeatability for complex ceramic components. Powder compaction tooling sets are made in a combination of carbide, steel, coated-steel, or ceramic based on the specific production conditions. Tooling sets are compatible with common single- and multi-level press systems to minimize downtime for tool changes.

Powder compaction tooling is designed to overcome key challenges in the pressing stage of technical ceramics:

• Surface Defects: Die cavities and associated punches are polished to mirror-like finishes to prevent the transfer of surface defects to the ceramic component.
• Chipping: Material consistency is the foundation of reliable tooling that avoids chipping. Incoming materials are inspected to prevent quality issues in finished powder compaction tooling.
• Abrasive Wear: High-volume pressing creates friction between the ceramic material and powder compaction tooling. Hyperion application engineers recommend the best material to decrease abrasive wear over millions of cycles.

Reconditioning Services

After sufficient wear, powder compaction tooling can be refurbished or resurfaced to delay the purchase of new tooling sets. Hyperion offers reconditioning services in the United States and Europe for dies, punches, and full tool sets. Powder compaction tooling sets are visually and dimensionally inspected upon arrival, during refurbishing, and before shipment.

Powder compaction tooling sets are reworked to like-new conditions for seamless integration into production processes. Regular reconditioning services increase usable tool life, so new tooling purchases can be delayed and tooling spend decreases.

Your Strategic Tooling Partner

Pressing operations serve key growth industries across the globe. Hyperion is committed to providing a secure, stable supply of tooling to support industry growth. Beyond tooling design and machining capabilities, Hyperion offers reliability to manufacturers.

Supply Chain Stability

Hyperion has long-standing relationships with providers of ammonia paratungstate (APT), the main raw material for carbide tooling. In-house powder processing plants in the United States and France ensure material consistency from powder to finished tooling. Manufacturers gain supply chain security by leveraging Hyperion’s western-based supply chain.

Reliable Customer Service

Hyperion has a global team that is ready to deliver the reliable and fast service clients require from a compaction tooling provider. Local customer service teams are backed by an expert network of materials engineers, sintering experts, and grinding professionals to serve the specific needs of your project.