Precision Pelletizing with Heated Dies: The Complete Buyer’s Guide
When you’re forming pellets from powders—whether for materials science, battery research, ceramics, or pharmaceutical R&D—two variables determine success: pressure and temperature. A heated die integrates both, combining a robust dry‑pressing die set with a built‑in heater and a digital temperature controller to regulate heat during compaction. Shop Genomics offers a curated Heated Die Collection in multiple inner diameters (13 mm, 25 mm, 50 mm, and 76 mm), each rated for temperature control up to 250 °C via a PT‑100 sensor and WK‑1 controller for precise thermal management. [shopgenomics.com]
At a glance: The Heated Die Collection features temperature‑controlled dies up to 250 °C and multiple diameter options, enabling consistent pellet geometry and density across a range of materials. [shopgenomics.com]
Why Temperature Control Matters in Pellet Pressing
Powder compaction is sensitive to friction, moisture, and material phase behavior. Heating the die body can reduce interparticle friction, drive off residual solvents, and—in some systems—enable phase transitions that improve green strength and density uniformity. Shop Genomics’ heated dies are built specifically to deliver this thermal consistency: the designs integrate a PT‑100 heater/sensor and a WK‑1 digital temperature controller so you can set and hold a target temperature in 1 °C steps with rapid sampling for stability. [shopgenomics.com], [shopgenomics.com]
In practical terms, this means fewer cracked pellets, tighter thickness tolerances, and better repeatability across batches. The tight machining tolerances (≈0.01–0.02 mm) published for the series further support dimensional consistency. [shopgenomics.com], [shopgenomics.com]
Product Family Overview: Sizes & Core Specs
Shop Genomics lists the Heated Die Collection in four popular IDs—13 mm, 25 mm, 50 mm, and 76 mm—covering small‑format research pellets through larger‑format compacts. All models share the 250 °C temperature ceiling and digital control. [shopgenomics.com]
Two published spec sheets illustrate how capabilities scale with size:
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13 mm Heated Die (SDS13.H)
- Temp: up to 250 °C (PT‑100 heater/sensor with WK‑1 controller)
- Tolerance: 0.01–0.02 mm
- Max pressure: 20 tons
- Materials: W18Cr4V hardened carbon tool steel for core die and push rod; Cr12 hardened carbon mold steel for sleeve/ejector/support
- Notes: Designed for precise, small‑diameter cylindrical pellets; includes cylinder pellet ejector for efficient release. [shopgenomics.com]
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50 mm Heated Die (SDS50.H)
- Temp: up to 250 °C (PT‑100 + WK‑1 digital controller)
- Tolerance: 0.01–0.02 mm
- Max pressure: 200 tons
- Materials: Hardened steel construction for high durability under heavy loads
- Notes: Suited to high‑output, heavy‑duty operations needing large‑diameter, uniform pellets. [shopgenomics.com]
The collection landing page confirms the available diameters and digital controller standardization across SKUs; individual product pages publish granular specs like pressure limits, tolerances, and material callouts. [shopgenomics.com], [shopgenomics.com], [shopgenomics.com]
Key Engineering Features That Improve Outcomes
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Integrated Heating System (to 250 °C)
All heated dies in the collection offer controlled heating up to 250 °C, enabling you to optimize pellet density and mitigate defects related to cold pressing—especially for thermally assisted sintering workflows, battery electrode mixes, or ceramic precursors. [shopgenomics.com], [shopgenomics.com], [shopgenomics.com] -
PT‑100 Sensor + WK‑1 Digital Controller
The PT‑100 sensor provides accurate, stable temperature feedback, while the WK‑1 controller allows programmable setpoints and 1 °C step adjustments with fast sampling. This reduces overshoot and supports repeatable thermal profiles across batches. [shopgenomics.com], [shopgenomics.com] -
Precision‑Machined Tolerances (≈10–20 µm)
Tight ID/OD tolerances (0.01–0.02 mm) promote uniform compaction, which is critical for comparable density and mechanical strength across your pellets. [shopgenomics.com], [shopgenomics.com] -
Hardened Steel Construction for Longevity
The series uses hardened tool steels (e.g., W18Cr4V for core components and Cr12 for sleeves/ejectors/supports on specific models) to resist wear under high pressure and temperature cycling—key for labs and plants with frequent runs. [shopgenomics.com] -
Pellet Ejector & Accessory Set
Systems include a cylinder pellet ejector, push rods, thermal isolation plates, and support plates to streamline release and protect heat‑sensitive interfaces. [shopgenomics.com], [shopgenomics.com]
Common Use Cases Where Heated Dies Shine
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Battery & Energy Materials: Temperature‑assisted compaction of cathode/anode formulations can reduce binder viscosity during pressing and promote uniform particle packing—helping achieve more consistent electrochemical performance in lab cells. The heated die platform provides the 250 °C control and tight tolerances needed for repeatability. [shopgenomics.com], [shopgenomics.com]
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Ceramics & Advanced Materials: For ceramic powders and sintering precursors, controlled heat during pressing can improve green‑body integrity, minimizing microcracks that compromise downstream firing. The PT‑100 + WK‑1 control loop is designed for stable set‑and‑hold behavior. [shopgenomics.com], [shopgenomics.com]
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Pharmaceutical & Catalyst Pellets: When forming analytical tablets or catalyst pucks from hygroscopic or solvent‑laden powders, gentle heating drives off volatiles and enhances dimensional stability, aided by 10–20 µm tolerance levels. [shopgenomics.com], [shopgenomics.com]
How to Choose the Right Heated Die
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Pellet Diameter (Sample Size & Analysis Method)
- 13 mm: Popular for spectroscopy and small‑dose R&D pellets; supported with 20‑ton max pressure for robust compaction in a compact form factor. [shopgenomics.com]
- 50 mm: Scales up area for bulk tests or higher mass throughput; the model is engineered for up to 200 tons to maintain density across larger cross‑sections. [shopgenomics.com]
- 25 mm & 76 mm: Additional options listed on the collection page for intermediate and large formats; choose based on downstream measurement geometry and press capacity. [shopgenomics.com]
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Required Compaction Pressure
Match your press’s capacity to the die’s published limit. For example, the 13 mm unit lists 20‑ton max, while the 50 mm unit is rated up to 200 tons—underscoring how pressure capability scales with die size and intended workload. [shopgenomics.com], [shopgenomics.com] -
Thermal Profile & Dwell Time
If your formulation benefits from stepwise heating (e.g., pre‑heat, press, hold), the WK‑1 controller and 1 °C steps enable fine‑grained control for repeatable SOPs. [shopgenomics.com], [shopgenomics.com] -
Material Compatibility & Wear
Hardened tool steels (W18Cr4V/Cr12 in certain SKUs) and polished surfaces minimize abrasion and sticking, improving die longevity and surface finish on pellets—important for analytical reproducibility. [shopgenomics.com] -
Throughput & Ergonomics
Features like the cylinder pellet ejector accelerate release and reduce handling time—valuable in QA labs and pilot production lines. [shopgenomics.com], [shopgenomics.com]
Best Practices: Operation, Safety & Maintenance
- Safety First: Always wear protective goggles and appropriate PPE. Respect the published max pressure rating to avoid damage and safety hazards. [shopgenomics.com], [shopgenomics.com]
- Post‑Run Cleaning: After pressing, clean components with absolute ethyl alcohol and dry thoroughly; then store the die in a dry box with silica gel to prevent corrosion. [shopgenomics.com], [shopgenomics.com]
- Environmental Conditions: Maintain a controlled environment around 0–50 °C and <35% RH when operating the controller for optimal accuracy and stability (as specified on product pages). [shopgenomics.com], [shopgenomics.com]
- Process Consistency: Use the controller’s fine 1 °C step and rapid sampling to standardize recipes across runs, especially for materials sensitive to thermal gradients. [shopgenomics.com], [shopgenomics.com]
Real‑World Example Workflows
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Lithium‑Ion Electrode Pellet (13 mm)
- Pre‑heat die to 80–120 °C to reduce binder viscosity.
- Apply staged pressure up to your SOP limit, staying below the die’s 20‑ton rating.
- Hold for 1–3 minutes, then eject using the supplied ejector.
The tight tolerances help ensure consistent thickness and density across test cells. [shopgenomics.com]
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Large‑Diameter Ceramic Disc (50 mm)
- Pre‑condition the powder to target moisture, heat die to 150–200 °C.
- Ramp pressure in steps to avoid edge cracking, not exceeding 200 tons as specified.
- Controlled release and ejection protect edges on larger compacts. [shopgenomics.com]
FAQs
Q1: How hot can the dies go?
Up to 250 °C across the heated die lineup, using a PT‑100 sensor and a WK‑1 digital controller for accurate set‑and‑hold performance. [shopgenomics.com], [shopgenomics.com], [shopgenomics.com]
Q2: What pressure limits should I observe?
Refer to each product page: the 13 mm model is rated up to 20 tons, while the 50 mm model supports up to 200 tons. Select a die that matches your press capacity and pellet diameter. [shopgenomics.com], [shopgenomics.com]
Q3: What materials are used in construction?
Listings specify hardened tool steels for durability; for the 13 mm model, W18Cr4V is used for core components and Cr12 for sleeves/ejectors/supports. [shopgenomics.com]
Q4: What’s included with the die sets?
Typical kits include two core dies, a steel sleeve with PT‑100 heater/sensor, support plate, thermal isolation plate, push rod, cylinder pellet ejector, and the WK‑1 controller (verify on the specific SKU page). [shopgenomics.com], [shopgenomics.com]
Q5: Any cleaning or storage tips?
Clean with absolute ethyl alcohol after each run, then store in a dry box with silica gel to prevent rusting; never exceed the published tonnage. [shopgenomics.com], [shopgenomics.com]
Where to Buy (and How to Compare)
Start at the Heated Die Collection page to view all four sizes and quickly compare pricing and availability. For detailed specifications, consult the individual product pages—such as:
- 13 mm Diameter ID 250 °C Heated Die w/ Digital Controller for small‑format, high‑precision pellets (max 20 tons). [shopgenomics.com]
- 50 mm Diameter ID 250 °C Heated Die w/ Digital Controller for large pellets and heavy‑duty throughput (max 200 tons). [shopgenomics.com]
Tip: If you’re unsure which diameter/pressure profile best matches your press and SOP, shortlist two sizes and map their pressure ratings against your equipment’s max load, then standardize a temperature setpoint using the WK‑1 controller’s 1 °C increments for A/B testing. [shopgenomics.com], [shopgenomics.com]
