Founded in 1986 by Dr. Toni Leyendecker, CemeCon AG has grown to become the world market leader in diamond coating and a technological pioneer in PVD coatings for precision tools. The company’s innovative HiPIMS technology combines the benefits of all existing PVD processes, delivering exceptional economic and performance benefits.
CemeCon operates globally, serving key markets through coating centers in Germany, USA, China, Japan, and partnerships in countries like India, Taiwan, and Denmark. Its comprehensive expertise in coating services and plant engineering continues to set new standards in the industry.
Introduction to HiPIMS: The Future of PVD Coatings
High Power Impulse Magnetron Sputtering (HiPIMS) is heralded as the future of Physical Vapor Deposition (PVD) coatings. Combining the strengths of all existing coating processes, HiPIMS technology stands as a game-changer for cutting tools. CemeCon, a pioneer in this field, offers HiPIMS solutions that empower tool manufacturers and machinists to unlock unprecedented potential. But what makes HiPIMS so special? Let’s explore the unique advantages that set it apart.
Unmatched Physical and Chemical Properties
HiPIMS coatings are distinguished by their combination of exceptional hardness and toughness, smooth surfaces, and dense, fine-grained structures. These coatings also feature low compressive residual stresses, making them highly robust in demanding applications.
Dr.-Ing. Christoph Schiffers, Product Manager Technology at CemeCon, explains the significance of this combination: “Hardness alone is insufficient for superior coatings. While glass is hard, it is also brittle, making it unsuitable for high-stress machining applications. HiPIMS coatings, by combining hardness with balanced toughness, resist periodic cutting force peaks, even during interrupted cutting in milling or grooving operations.”
This unique combination is especially beneficial for smaller tools, where traditional coatings fail under stress. The result? A quantum leap in performance, durability, and versatility.
HiPIMS: The Process Advantage
HiPIMS is an evolution of sputtering technology, and it eliminates one of the primary drawbacks of other PVD processes: droplets. Unlike traditional coatings, HiPIMS produces smooth, defect-free surfaces. Additionally, the technology’s flexibility allows virtually any coating composition—such as TiB2—to be applied to a wide variety of substrates, including ceramics and cubic boron nitride (CBN).
From micro tools requiring ultra-thin coatings to inserts needing a layer thickness of up to 12 µm, HiPIMS accommodates an impressive range of tool types and sizes. CemeCon takes this a step further by tailoring each coating to the specific requirements of the tool. This customization ensures seamless integration with the substrate and geometry, delivering optimal machining solutions.
Tailored Solutions with CemeCon Engineering
CemeCon’s approach goes beyond offering standardized coatings. Through collaborative engineering with tool manufacturers, they create bespoke solutions optimized for specific applications. Parameters such as coating material, thickness, pre-treatment, and finishing are meticulously adjusted to meet customer needs.
For manufacturers with in-house coating lines, CemeCon provides the CC800® HiPIMS system. This allows complete control over all HiPIMS parameters, enabling high levels of individualization and differentiation in a competitive market.
Technological Excellence: The CemeCon Advantage
HiPIMS technology’s standout feature lies in its high-energy power pulses, which enable finely adjustable coating parameters. CemeCon’s proprietary pulse generators are designed specifically for cutting tool applications, ensuring unmatched performance.
A key innovation is the synchronization of HiPIMS pulses with the substrate table, allowing coatings to grow purposefully on tools. This significantly reduces residual stresses, enabling the creation of much thicker coatings compared to other processes. For small and micro tools, this means sharp cutting edges with dense, stress-free coatings, ensuring process safety and enhanced durability.
Dr.-Ing. Biljana Mesic, Technology Development Manager PVD, emphasizes:
“Our coherent overall concept—combining pulse generators, coating systems, and decades of experience—ensures that HiPIMS delivers exceptional results. It’s high-tech made simple for the user.”
Ease of Operation and Unparalleled Performance
Despite its technological complexity, CemeCon has simplified HiPIMS operation for users. The system’s control mechanisms are as intuitive as driving a car with ABS brakes. Christoph Schiffers highlights this customer-centric design:
“HiPIMS technology is automated and user-friendly, allowing anyone to achieve outstanding results. The dense layer structure’s properties represent a quantum leap for premium tool coatings.”
Global Leadership and Continuous Innovation
CemeCon’s expertise is rooted in over three decades of research, development, and practical experience. Operating one of the largest coating centers in the world at its headquarters in Würselen, Germany, CemeCon finishes over 80,000 precision tools daily with premium coatings. This unparalleled scale and expertise position the company as a global leader.
CemeCon designs and produces its coating systems in-house, continuously refining them based on insights from its own operations and customer feedback. With coating systems integrated into production facilities worldwide, the company has established itself as a trusted partner for tool manufacturers across industries.
HiPIMS: A Game-Changer in Tool Coatings
HiPIMS technology has redefined cutting tool coatings by delivering dense layer structures with unique physical properties. Its ability to combine hardness and toughness, minimize residual stresses, and accommodate diverse substrates makes it an industry benchmark.
CemeCon’s dedication to customer success is evident in its collaborative engineering approach, bespoke solutions, and user-friendly systems. Whether through its coating services or in-house systems, CemeCon empowers manufacturers to achieve unparalleled performance and stand out in competitive markets.
Securing a Competitive Edge with HiPIMS
HiPIMS coatings are a quantum leap for cutting tools, offering unmatched performance, flexibility, and durability. Whether through in-house systems like the CC800® HiPIMS or collaborative engineering with CemeCon experts, manufacturers can unlock the full potential of their precision tools and secure a competitive edge in demanding markets.
CemeCon’s HiPIMS technology represents a transformative leap in the field of cutting tool coatings, combining unparalleled smoothness, hardness, and toughness with a highly customizable approach tailored to specific machining requirements. By aligning cutting-edge research, decades of expertise, and practical experience, CemeCon has not only perfected the HiPIMS process but also made it accessible and efficient for tool manufacturers worldwide. Whether through their advanced coating systems or expert support in developing bespoke solutions, CemeCon empowers manufacturers to achieve superior tool performance, extended tool life, and a distinct competitive edge. With HiPIMS, the future of precision machining coatings is here, setting new benchmarks in productivity, quality, and innovation.