Services

Advanced Project Management and Lean Six Sigma Driven Performance Improvement

With more than 15 years of experience in project management, BS PM Solutions has successfully delivered over 100 projects with a total managed volume exceeding €25 million. This includes the planning, execution, and leadership of complex industrial projects, as well as direct reporting and representation at board level and technical conferences. Individual project values have reached up to €5 million.

 

Certified as a Six Sigma Black Belt with strong expertise in Lean Six Sigma, the focus lies on delivering measurable improvements in efficiency, quality, and cost performance. Proven results include up to 50 percent reduction in time to market, 80% reduction in tool development time through DoE, simulation, and additive manufacturing, and significant improvements in production performance, including 25% shorter lead times and 16% reduction in failure costs.

 

Experience also includes the successful implementation of manufacturing and recycling lines, the digitalization of around 70 machines using AI based systems, and the development and industrialization of new processes for next generation products.

Optimizing Carbide Tool Manufacturing in a Changing Cost Environment

The tungsten carbide market is facing increasing cost pressure driven by supply constraints, geopolitical factors, and rising demand. As raw materials account for the majority of carbide tool manufacturing costs, companies must rethink production processes, technology deployment, and material strategies to remain competitive.

We support manufacturers in powder metallurgy and carbide tool production in identifying process inefficiencies, stabilizing operations, and reducing variability through data-driven methodologies and Six Sigma principles. By integrating modern production technologies, aligned equipment concepts, and advanced inline process analytics, we enable more stable, efficient, and scalable manufacturing systems.

At the same time, we help companies evolve their product strategies to address rising material costs. This includes reducing tungsten carbide consumption, improving recycling concepts, and evaluating alternative material systems such as NbC, TiC(N), or multi-carbide solutions for specific applications. The result is more resilient production, improved cost efficiency, and a future-ready product portfolio.

 

Powder mixing & preparation

The development of high-performance cemented carbide products begins with a thorough analysis and selection of suitable raw materials. Based on the specific application, processing requirements, and targeted product performance, appropriate raw materials are evaluated to ensure optimal functionality and reliability.

This is followed by the design and optimization of mixing processes, including the selection of suitable equipment for weighing, attrition milling, and drying operations such as spray drying or tumble drying. These steps ensure homogeneous powder mixtures and stable material properties.

For extrusion-based manufacturing routes, dedicated feedstock development is performed, including process design and equipment selection tailored to different binder systems. This ensures consistent extrusion behavior and reliable downstream processing.

In addition, powder pressing feedstocks and ready-to-press (RTP) powders are developed with a strong focus on flowability, homogeneity, and compaction behavior. Appropriate equipment and process parameters are defined to guarantee stable pressing conditions and high-quality green bodies.

Extrusion & pressing Technology Development

Comprehensive expertise in the development of extrusion and pressing technologies for cemented carbide applications. This includes the design and development of fixtures and extrusion dies for spiral hole rods with up to six internal channels as well as solid rods. Additively manufactured tooling components are integrated where beneficial, enabling highly flexible solutions up to fully automated extrusion lines with inline quality inspection.

Extrusion processes are developed and optimized end-to-end, taking into account feedstock properties, process stability, and final component quality. This includes both screw and piston extrusion technologies, with a strong focus on quality assurance and controlled shrinkage behavior during sintering.

Innovative extrusion concepts are developed, such as twisted and application-specific internal coolant channel geometries, enabling enhanced tool performance and new product designs.

In addition, pressing tools and equipment are developed for rod geometries and customer-specific components. This includes the selection of suitable pressing systems based on the production portfolio, as well as the development and optimization of powder pressing processes tailored to material behavior and quality requirements.

Advanced pressing kinematics complete the portfolio, enabling the realization of complex cylindrical components with helical or functionally optimized geometries.

Expertise in sintering technology for Cemented Carbide

Comprehensive expertise is provided in the selection, development, and optimization of sintering technologies for cemented carbide components. The focus lies on identifying and selecting suitable sintering furnaces based on specific material and process requirements, including different binder systems such as paraffin or cellulose, as well as the necessary peripheral equipment for gas supply and furnace operation.

Sintering processes are developed and optimized with particular attention to temperature profiles, controlled gas flow, and precise atmosphere management. This ensures the reliable removal of process additives and accurate control of the carbon balance, which is essential for achieving the targeted chemical and physical properties of the final components.

In addition, efficient material handling concepts are developed to support stable and high-quality serial production. This includes the design of sintering trays made from materials such as graphite or CFC, optimized loading and unloading strategies, and the definition of suitable separation coatings to prevent sticking, deformation, or surface defects while maintaining high productivity.

Furthermore, support is provided in the planning and setup of cemented carbide laboratories. This includes the selection of appropriate testing and analysis equipment for evaluating the physical and chemical properties of powders and sintered components, enabling reliable process development, quality assurance, and long-term production stability.

Finishing & grinding

Comprehensive expertise is provided in the selection and application of grinding, cutting, and tool grinding technologies for the production of cylindrical cemented carbide rods and high-performance cutting tools. This includes the evaluation and selection of suitable grinding and cutting machines as well as grinding wheels to ensure maximum form accuracy, excellent surface quality, and high productivity in serial manufacturing.

In addition, advanced cutting geometry development is carried out for a wide range of tool materials, including cemented carbide, cutting ceramics, PcBN, and diamond tools such as PCD and MCD. Tool geometries are specifically designed to meet application requirements and optimize cutting performance, tool life, and process stability.

The portfolio is complemented by the integration of advanced laser processing technologies. High-energy laser systems are applied for the manufacturing of high-performance cutting edges, chip breakers, and complex micro-tool geometries, enabling innovative tool designs and enhanced machining performance.

High performance cutting tool engineering

Advanced cutting tool design is supporte through the development of optimized macro- and micro-geometries, combined with the selection of the most suitable substrate for each machining task. This includes cemented carbides with varying cobalt contents as well as advanced cutting materials such as Si₃N₄, SiAlON, SiC, Al₂O₃, PcBN, and PCD, ensuring optimal performance for a wide range of applications.

Manufacturing processes are systematically analyzed and optimized to achieve stable, high-performance production conditions. This includes the evaluation of manufacturing parameters, identification of process limitations, and the development of robust process windows to ensure consistent quality and long-term production efficiency.

In addition, suitable PVD and CVD coating systems are selected and evaluated based on the specific application requirements. Coating analysis and performance assessment are carried out with a focus on tribological behavior, wear resistance, and overall tool performance, enabling the selection of optimized coating systems for demanding machining operations.