Precision tools driving EV and hybrid composites manufacturing

At the core of lightweight, high-speed and energy-efficient electric and hybrid vehicles, composite materials play a crucial role in manufacturing advanced components. However, working with composites demands more than just selecting the right materials; it requires a new generation of precision tooling.

The Composites Challenge
Composites such as carbon fiber-reinforced polymers (CFRPs) and glass fiber composites (GFRPs) are not easy to work with. Their multi-layered structure, fiber orientation and abrasive nature make them resistant to traditional machining techniques. Unlike metals like steel, composites don’t deform, they fracture. That means every cut must be calculated, every edge protected, and every tool enhanced.
“The challenge with machining composites is that your cutting tool needs to be both sharp and abrasion-resistant at the same time. It is a delicate balancing act,” said Chris Stewart, Kennametal Key Account Manager.

Diamonds are Forever
Diamonds aren’t just a luxury; they are essential in composites machining. One of the most significant innovations from Kennametal is the introduction of KBDM PCD Face Mills. These polycrystalline diamond tools are a high-density platform designed for faster machining cycles and precise surface finishing of composite components. Their extreme hardness and thermal stability enable them to stay sharp, providing clean, delamination-free finishes on critical parts such as battery enclosures, structural panels, and motor housings. Additionally, the KD1400™ and KD1425™ grades, when combined with the cutter bodies, offer improved wear resistance and edge strength.

Drilling Stacks
Drilling into composites—especially when combined with metal layers—requires tools that can manage heat, resist wear, and maintain hole integrity. Kennametal’s DAL drills can be used in all combinations of stacks such as CFRP-Ti-Al, CFRP-Ti, CFRP-Al, and also straight Ti or Al. They feature a double-angle point design and minimise burrs when exiting the metal side of the stack.

Routing with ROCO
Routing operations, which are vital for trimming, profiling, pocketing, side milling, and slotting composite parts, have also experienced significant innovation. Kennametal’s ROCO burr router geometry pushes cutting forces both upward and downward, reducing delamination during side milling and slotting. Meanwhile, the down-cut routers from Kennametal produce clean top-surface finishes by pushing chips downward, making them ideal for visible parts where aesthetics and surface quality are important.
“ROCO routers have seen great success across a range of composite materials and applications,” said Katie Myers, Kennametal Marketing Product Manager. “Our geometry paired with our new KCC05A CVD diamond coating grade is providing exceptional tool life and the ability to run at higher cutting parameters.”
Additive Manufacturing in Tool Design
Manufacturers are also leveraging additive manufacturing to create custom tool bodies with internal cooling channels and optimised weight distribution. These 3D-printed tools are lighter, more rigid and capable of handling complex geometries, especially in deep cavity applications like electric motor housings.
For example, Kennametal’s 3D printed stator bore tool for machining aluminium e-motor housings is capable of machining three large diameters in just one operation. The tool features airfoil-shaped arms with internal coolant channels, enabled by additive manufacturing, which improves chip evacuation and cooling. It also includes carbon fiber components to further reduce weight and improve handling.
Additionally, Kennametal’s RIQ inserts are ideal for machining large diameters, while the RIR inserts deliver precision for smaller diameters. When paired with Kenionic™ tool holders, these inserts form a high-performance reaming solution.

Beyond the Shop Floor
The influence of these tooling innovations extends far beyond the shop. By enabling the efficient processing of composites, advanced tools contribute directly to vehicle performance and sustainability. Lighter components reduce energy consumption and extend battery life. Precision machining minimises material waste and rework. And smarter tools help manufacturers scale production while maintaining quality and consistency.
Some of the latest tools are embedded with smart sensors that monitor temperature, vibration and wear in real time. These tools communicate with CNC systems to dynamically adjust cutting parameters, reducing the risk of tool failure and ensuring consistent part quality. In high-volume EV production environments, where production time and repeatability are paramount, this level of intelligence is becoming a real competitive advantage.

Longevity in Composites Tooling
In high-demand manufacturing environments, tool longevity isn’t just a convenience; it’s a requirement. The future of composites tooling lies in deeper integration with digital manufacturing ecosystems. As EV and hybrid vehicles become more sophisticated, the tools that shape them must also evolve to become faster, smarter and more adaptable. Tooling is no longer a behind-the-scenes operation; it’s now a critical part of the overall metal cutting strategy.
“Innovation is our priority,” said Myers. “With all of the advancements being made in composite materials, our tools are constantly evolving to continue to provide a high level of performance and reliability in materials outside of the metals we’ve traditionally worked with.”

Conclusion
With advanced solutions like PCD face mills, stack-optimised drills, innovative router geometries and additive-manufactured tool bodies, manufacturers can meet the growing demands of composites machining head-on. The proper tooling just doesn’t cut it anymore. It must accelerate production, improve quality and support sustainability.