If you work with tungsten carbide parts—whether you’re shaping seal rings, trimming drill bits, or resizing wear liners—you’ve probably asked: “Can tungsten carbide even be cut?” It’s a fair question. After all, tungsten carbide is one of the hardest industrial materials (Mohs hardness 8.5–9, just below diamond), so grabbing a regular steel saw or grinder won’t work. The good news? Yes, tungsten carbide can be cut—but only with specialized tools and methods that match its extreme hardness. In this post, I’ll break down why ordinary tools fail, the 4 most effective ways to cut tungsten carbide, key tips to avoid ruining parts, and real-world examples from factories and workshops. No complex machining jargon—just practical advice you can use to get clean, precise cuts.
First: Why Ordinary Tools Can’t Cut Tungsten Carbide
Before we talk about how to cut it, let’s clarify why your go-to tools won’t work. Tungsten carbide’s hardness is its superpower—but it also makes it nearly impossible to cut with standard equipment:
- Steel saws/ blades: A steel hacksaw or circular saw blade will dull within seconds. Tungsten carbide is harder than steel, so the blade grinds against the material instead of cutting it—you’ll end up with a ruined blade and an uncut part.
- Regular grinding wheels: Most grinding wheels are made of aluminum oxide or silicon carbide, which are softer than tungsten carbide. These wheels will wear down fast, leaving rough edges and no progress.
- Drills (even high-speed steel): A steel drill bit will bounce off tungsten carbide, or worse, shatter. You can’t “drill through” it with ordinary tools—you need a method that bypasses brute force.
Real example: A new technician once tried to trim a tungsten carbide seal ring with a steel band saw. After 20 minutes, the saw blade was completely dull, and the seal ring had only a tiny scratch. We switched to a diamond blade, and the cut took 2 minutes—clean and precise.
4 Effective Ways to Cut Tungsten Carbide (With Examples)
Cutting tungsten carbide isn’t about “force”—it’s about using tools that match or exceed its hardness, or using energy to erode the material instead of slicing it. Here are the 4 most common methods used in industry, plus when to choose each:
1. Diamond Tool Cutting (Most Common for Basic Cuts)
Diamond is the only natural material harder than tungsten carbide—so diamond-coated or diamond-impregnated tools are the go-to for simple cuts (like trimming, slicing, or grinding edges).
- Tools used: Diamond saw blades (for straight cuts), diamond grinding wheels (for shaping edges), diamond drills (for holes).
- How it works: The diamond particles on the tool’s surface grind away tiny bits of tungsten carbide, creating a clean cut. It’s slow but precise—no heat damage if done right.
- Best for:
- Straight cuts on flat parts (e.g., trimming a tungsten carbide wear plate to size).
- Shaping edges (e.g., beveling a seal ring to fit a pump).
- Drilling small holes (e.g., adding a mounting hole to a tungsten carbide sensor bracket).
Pro tip: Use a wet-cutting setup (spray water or coolant) to keep the diamond tool cool—heat can wear down diamonds faster and cause the tungsten carbide to crack.
2. EDM (Electrical Discharge Machining) (Best for Complex Shapes)
EDM (also called “spark machining”) doesn’t use a physical blade—it uses electrical sparks to “erode” tungsten carbide into shape. This is perfect for parts with intricate details that diamond tools can’t handle.
- Tools used: EDM machines (wire EDM for thin parts, sinker EDM for 3D shapes).
- How it works: The machine creates a small gap between a metal electrode (e.g., a thin wire or a custom-shaped tool) and the tungsten carbide. High-voltage sparks jump across the gap, melting and vaporizing tiny pieces of tungsten carbide—slowly carving the desired shape.
- Best for:
- Complex grooves or slots (e.g., cutting the flutes in a tungsten carbide drill bit).
- Intricate 3D shapes (e.g., making a custom tungsten carbide mold insert).
- Thin or delicate parts (e.g., a 0.5mm-thick tungsten carbide shim) that would crack with diamond cutting.
Example: We once made a tungsten carbide valve core with 4 tiny, curved channels. Wire EDM was the only way to cut the channels without breaking the thin walls—diamond tools would have snapped the part.
3. Laser Cutting (Great for Thin Parts & Precision)
Laser cutting uses a high-energy laser beam to melt or vaporize tungsten carbide. It’s fast, precise, and ideal for thin sheets or parts that need tight tolerances.
- Tools used: Fiber laser cutters (most effective for tungsten carbide—they handle hard materials better than CO₂ lasers).
- How it works: The laser beam focuses intense heat on a small area of tungsten carbide, melting the material. A gas jet (usually nitrogen) blows away the molten debris, leaving a clean cut edge.
- Best for:
- Thin tungsten carbide sheets (e.g., cutting 1–3mm thick sheets into gaskets or washers).
- Fine details or small holes (e.g., adding a pattern to a tungsten carbide decorative plate—yes, it’s used in high-end industrial decor too!).
- High-volume production (lasers cut faster than diamond tools for thin parts).
Note: Laser cutting works best for parts under 5mm thick. Thicker tungsten carbide needs more laser power, which can cause heat damage (like warping or cracking).
4. Waterjet Cutting (Ideal for Thick or Heat-Sensitive Parts)
Waterjet cutting uses a high-pressure stream of water mixed with abrasive particles (usually garnet) to “sandblast” through tungsten carbide. It’s a cold-cutting method—no heat, so no risk of warping or cracking.
- Tools used: Abrasive waterjet machines.
- How it works: The machine pushes water through a tiny nozzle (0.1–0.3mm) at 30,000–60,000 PSI (that’s 2,000+ times atmospheric pressure!). The water mixes with garnet abrasive, creating a jet that grinds through tungsten carbide like sandpaper through wood.
- Best for:
- Thick tungsten carbide parts (e.g., cutting a 100mm thick tungsten carbide block into a wear liner).
- Heat-sensitive parts (e.g., tungsten carbide parts for medical devices, where heat could change their properties).
- Large parts (e.g., trimming a 2m long tungsten carbide conveyor belt scraper).
Fun fact: Waterjet cutting can cut through nearly any material—we’ve used it to cut tungsten carbide and steel in the same part, no tool changes needed!
3 Key Tips to Avoid Ruining Tungsten Carbide When Cutting
Even with the right tools, cutting tungsten carbide takes care—its brittleness means one mistake can crack the part. Here’s what to watch for:
1. Always Cool the Part (No Heat Spots!)
Tungsten carbide is brittle, and heat causes stress. If you cut it without cooling (e.g., dry diamond grinding), heat can build up in small spots, leading to cracks.
- Solution: Use coolant for diamond/EDM cutting, or stick to cold methods (waterjet) for heat-sensitive parts. For small jobs, even a spray bottle of water can help.
2. Secure the Part Tightly (No Vibration!)
Vibration during cutting can make the tool “jump,” leaving rough edges or cracking the part. For example, if a tungsten carbide seal ring isn’t clamped down while cutting, a diamond saw might wobble and chip the edge.
- Solution: Use clamps or a vice with soft jaws (to avoid scratching the part) to hold it firmly. For delicate parts, use a vacuum chuck (suction holds it in place) instead of clamps.
3. Don’t Rush—Slow Cuts = Clean Cuts
Tungsten carbide cuts slowly by nature. Rushing (e.g., pushing a diamond saw too hard, or cranking up the laser speed) will:
- Wear out tools faster (diamond blades will dull, laser nozzles will clog).
- Leave rough edges that need extra sanding.
- Increase the risk of cracking.
- Solution: Follow the tool’s recommended speed—for diamond cutting, that’s usually 1–5 inches per minute (IPM) depending on thickness.
Common Myth: “Cutting Tungsten Carbide Is Too Expensive”
A lot of people avoid cutting tungsten carbide because they think it’s costly—but it’s often cheaper than buying a new custom part. For example:
- If you have a tungsten carbide wear liner that’s 1cm too long, cutting it down costs $20–$50 (with diamond tools). Buying a new custom liner could cost $200+.
- EDM for a complex drill bit groove costs $50–$100, but it lets you reuse a $300 tungsten carbide blank instead of throwing it away.
The key is choosing the right method for the job—simple cuts = cheap (diamond), complex cuts = more investment (EDM/laser), but still cheaper than replacing parts.
Final Takeaway: Tungsten Carbide Can Be Cut—Just Pick the Right Tool
Tungsten carbide’s hardness doesn’t make it “uncuttable”—it just means you need to work with its properties, not against them. For straight cuts or grinding, use diamond tools. For complex shapes, EDM is your friend. For thin parts, laser cutting is fast. For thick or heat-sensitive parts, go with waterjet.
If you’re unsure which method to use for your part—say, a thick tungsten carbide seal ring that needs a complex slot—reach out. We can help you choose the cheapest, most precise method, and even connect you with trusted cutting partners if you don’t have the right equipment. After all, the goal isn’t just to cut tungsten carbide—it’s to cut it right, so your part works like new.
