DLC coatings in mould making – the key difference
In mould making, DLC coatings (diamond-like-carbon) offer a unique combination of wear protection, reduced friction, effective corrosion protection and high precision. Cost-effectiveness and process reliability are significantly improved by service lives up to ten times longer and the resulting lower maintenance effort. In many applications, the coating even enables lubricant-free operation.
The results become apparent very quickly during operation:
- Longer service life
- Reduced maintenance and downtime
- Higher process reliability
What is a diamond-like carbon coating?
The diamond-like carbon coating is an extremely hard, thin layer of carbon with characteristics similar to those of diamond. It is applied to the surface of the standard components using PVD or CVD processes in order to achieve a high surface hardness.
Characteristics of Meusburger DLC coatings:
- Coating thickness: ~ 2 µm
- Hardness: ~ 3000 HV
- Coefficient of friction against steel: 0.10–0.15
- Colour: black grey
Thanks to the low coating thickness, the geometry and surface finish of the standard components are fully preserved – a crucial advantage for precision applications in mould making.
Less wear, maximum service life
Guiding elements as well as centring units and locks in particular are subject to high wear due to friction when opening and closing the mould. Thanks to its very low coefficient of friction, the DLC coating ensures excellent sliding properties and significantly reduces adhesive wear. This results in reduced maintenance requirements, longer service life and, ultimately, lower operating costs.
Clean, lubricant-free operation
A classic problem in injection moulding: lubricants near the cavity lead to contamination. DLC coated sliding surfaces enable dry operation here.
This results in clear advantages:
- No contamination on components – even with light-coloured plastics
- Reduced friction for smooth operation of the slides
- Ideal for sensitive optical or medical components
Reliable even without any maintenance
Ejectors are often difficult to access and therefore difficult to lubricate. This can lead to a lack of lubrication and ultimately to fretting of the ejectors. DLC-coated ejectors are the ideal way to avoid this, thanks to their excellent dry-running properties and high corrosion resistance. When processing abrasive plastics (e.g. glass fibre reinforced plastics), the DLC coating also provides effective protection against increased abrasion.
Significantly longer maintenance intervals
In order to meet the high mechanical demands of the switching elements on latch locks, these are DLC coated. This enables an extended service life. Due to the DLC-coated sliding elements, the maintenance intervals for lubrication of two-stage ejectors is lengthened from 100,000 strokes to 300,000 strokes.
Economic efficiency: Costs vs. benefits of DLC coating
DLC coatings are initially more expensive to purchase than standard solutions. However, coating costs usually account for only a small proportion of the total mould costs. It is therefore crucial to take a holistic view across the entire life cycle.
The significantly extended life and reduced maintenance effort result in clear economic benefits in practice:
- lower maintenance costs
- reduced downtime
- less wear and fewer spare parts required
- higher process reliability
- increased productivity
In many applications, the higher initial costs are recouped within a short space of time through savings in day-to-day operations.
Conclusion: DLC coatings as a competitive advantage in mould making
DLC coatings are a key factor in reducing wear and stabilising processes. They extend life, reduce maintenance costs and boost productivity in the long term – particularly in demanding applications.
FAQs on DLC coatings
What are DLC coatings?
DLC coatings are diamond-like carbon layers that protect components from wear, friction and corrosion.
How much does a DLC coating cost?
The costs vary depending on the component and application. In most cases, the cost of the coating accounts for only a small proportion of the total mould costs and pays for itself very quickly thanks to its longer life.
How thick is a DLC coating?
A coating thickness of around 2 µm has proven effective for standard components in mould making.
How long does a DLC coating last?
The DLC coating can increase the life of standard components by a factor of 10.
When is a DLC coating particularly worthwhile in mould making?
For moving components subject to heavy loads and high quantities.
