US Synthetic Bearings Site

PCD Development

The PCD compacts used in US Synthetic dies are subjected to rigorous testing to ensure that they meet the needs of our customers. More

USS Wiredie Technology

What distinguishes US Synthetic Wire Dies PCD dies from the competition?

Consider these four key advantages:

1. Advanced Diamond Sintering Processes

Polycrystalline diamond sintering bonds a mass of small diamond particles into a larger, coherent structure. Sintered polycrystalline diamond provides greater toughness and durability when compared to single crystals because the individual crystals in a sintered body are randomly oriented. This prevents cracks from propagating along the weak planes where traditional diamond crystals cleave most easily. The random orientation of the diamond grains provides uniform wear on the die while maintaining the thermal conductivity and hardness of diamond.

2. High-Pressure, High-Temperature Technology

Diamond sintering requires the application of extreme heat and pressure. Typically, diamond is sintered at a temperature of around 1400°C (2550°F). At room pressure, these extreme temperatures would cause the diamond to revert to graphite. Maintaining extremely high pressure during the sintering process allows the diamond to remain in its natural form (see figure). This typically requires pressures of around 60 kbar (nearly 1,000,000 psi)—the equivalent of a 240 km (160 mile) high column of granite.

To achieve these extremely high temperatures and pressures simultaneously, US Synthetic Wire Die uses proprietary cubic press technology. The cubic press consists of six large pistons, each of which is capable of supplying several thousand tons of force. Each piston pushes on a tungsten carbide anvil, which in turn compresses a cubic pressure cell that contains the raw materials (carbide and diamond crystals). As soon as the cubic press reaches the desired pressure, electric current flows through a resistance heater embedded in the pressure cell to generate the required high temperatures. These conditions are maintained long enough to ensure complete diamond-to-diamond bonding of the individual crystals.


State-of-the-art manufacturing processes—including proprietary cubic presses that apply nearly 1 million pounds of uniform pressure and generate temperatures of 1,400° Celsius—are used to synthesize US Synthetic's wire dies, the industry’s strongest and most durable.

3. New Innovations through Research and Development

At US Synthetic Wire Die, experienced research and development engineers create new innovations for strengthening and improving our wire die products. Also, USS Wire Die works directly with the wire mills to customize materials and dimensions to meet unique, exacting specifications, all backed by the US Synthetic promise of the highest quality.

4. One of the World’s Most Advanced Material Testing Facilities

Extensive quality testing ensures every US Synthetic wire die meets the highest quality standards. This includes abrasive wear testing, ultrasonic and electron microscope scans, and other rigorous quality tests. ISO 9000-certified since 1993, USS Wire Die's testing lab has the ability to run tests in a variety of materials best suited to the application, and perform more than 15,000 hours of testing per year and is capable of conducting more than 400 test programs annually.


In-house abrasion tests have shown US Synthetic Wire Die materials to have dramatically better performance than leading competitors. In fact, in two field case studies using stainless steel wire, the US Synthetic die lasted more than twice as long as other PCD dies.