CDT Does It Again with Custom Electroplated Solution for the Energy Sector

What makes CDT stand out in the world of superabrasive solutions? It’s not just our products—it’s our people and our values. At Continental Diamond Tool, we live by GRIT: being a Global, Responsive, Innovative Team. And just like the team behind them, our tools are built with GRIT—engineered to perform with precision, durability, and purpose. Once again, our team delivered a standout example of what that means in practice.

This time, the challenge came from a company in the alternate energy sector—an organization pushing the boundaries of energy technology to build a more secure, efficient, and resilient infrastructure for tomorrow. They needed a large-diameter electroplated grinding wheel capable of meeting unique operational demands. Our Plated Department engineered a custom solution with a complex geometry and aluminum core to get the job done.

A Specialized Tool for a Demanding Application

This customer needed a grinding solution that could take on a particularly difficult challenge: shaping silicon carbide into a complex form with a wheel that would be nearly impossible to dress using conventional methods. It was a new application for a newer customer working in a rapidly evolving field driven by breakthrough technology—where precision and reliability were critical, but few proven solutions existed.

Plated grinding wheels proved to be the ideal choice. The application required significant stock removal from a large workpiece while maintaining a highly intricate form and holding tight tolerances. Because the form couldn’t be redressed, the wheel needed to maintain its geometry throughout the process—something CDT’s electroplated tools are engineered to do exceptionally well.

The application also required a grinding wheel much larger than what’s typical for plated products—no problem for CDT, thanks to our oversized plating tanks that can accommodate large diameters up to 38 inches without the need for segmentation. To reduce the overall weight while maintaining structural integrity, our engineers custom-designed the wheel with an aluminum core—an uncommon material for electroplating that few plating manufacturers are skilled at handling. Backed by our team’s expertise and manufacturing capabilities, the entire process—from order to delivery—was completed in under our standard lead time of 5 weeks. (For customers with even tighter deadlines, we also offer a RUSH program that can cut lead times in half for an additional fee—contact our sales team for more information.)

Precision Engineering Backed by Quality Assurance

What added to the complexity of this project was the combination of a highly detailed design and exceptionally tight tolerances. The customer required tolerances as precise as ±0.0010" across critical features, with the bore needing to meet a strict +0.0016" / -0.0000" specification (H7). Adding to the challenge, the wheel featured a custom aluminum core—an uncommon choice for electroplated products. Because aluminum oxidizes quickly, it demands a specialized pretreatment process that not all plating manufacturers are experienced or equipped to handle. 

This is where CDT’s commitment to quality makes all the difference. Thanks to CDT’s in-house expertise, we ensure strong, consistent adhesion while meeting all performance and quality requirements.

Our CNC department machines the core with robotic precision for consistent, repeatable results, while our skilled technicians apply masking by hand to ensure abrasive is placed exactly where it’s needed. Plating specialists carefully control timing and chemistry for optimal bond performance—but the real proof comes during inspection.

Every custom plated product at CDT undergoes rigorous quality checks using advanced metrology equipment, including:

• Keyence IM-8000 for fast, high-accuracy dimensional measurement

• Keyence VHX-960 digital microscope for surface structure and grit analysis

• Zoller Venturion for presetting and edge geometry verification

• Mitutoyo CMM for precise 3D inspection of critical tolerances

These tools—and the trained experts who use them—ensure that every wheel we deliver meets exacting performance standards before it ever reaches the customer.

Why CDT Plating?

Since launching our plating line four decades ago, CDT has custom-engineered more than 25,000 unique plated SKUs across a wide range of industries and applications.

We offer:

• Proven Experience – Deep expertise in solving complex, nonstandard grinding challenges, paired with the efficiency to deliver simple, standard forms with speed

• High-Capacity Infrastructure – More than 500 plating tanks in the U.S., with additional capacity expanding in Europe

• Innovation – R&D engineering expertise and application support to optimize wheel life and grinding performance

• Precision – In-house inspection tools for coupon measurement by expert technicians ensure every product meets exacting standards

• Versatility – Ability to handle extremely large diameters, unusual substrates, complex geometries, and more

• Sustainability – Strip and replate services to extend tool life, reduce waste, and support your long-term success

If other manufacturers say it can’t be done, chances are we already have.

Projects like this one for the energy sector are a clear example of CDT’s GRIT in action. With a global mindset, a responsive team, and an innovative custom-engineered approach, our Plated Department delivered a solution where others could not.

Do you have a challenging application that could benefit from CDT’s plated solutions? Let’s talk. Our team is here to help.