SAG Tools Range (Shape Adaptive Grinding)

Precision Polishing Tools

SAG-Tek's precision polishing tools are engineered for Shape Adaptive Grinding, a process that uses compliant, pressure-controlled contact to achieve consistent material removal and mirror-grade surface finishes on freeform, curved, and complex 3D geometries.

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Tools Range

SAG Tools Range

Each tool is engineered for a specific class of surface and component profile. All tools use compliant, pressure-controlled contact, conforming to the workpiece. Available in resin-bond and nickel-bond diamond grades for different finishes.

Teardrop
SAG Tool

Teardrop

Optimised for aspheric, freeform, and complex 3D surfaces. The teardrop geometry delivers consistent SAG contact on radii that bonnet or cap tools cannot. Teardrop tools are often used in a similar fashion to ball nose cutters.

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Bonnet
SAG Tool

Bonnet

The bonnet provides consistent contact on convex, concave planar or freeform surfaces. Delivering controlled and uniform material removal on mould cavities, turbine blades, and curved optical elements.

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Cap
SAG Tool

Cap

The most versatile SAG tool geometry. The cap tool can be used in most applications. This jack of all trades tool can be used to polish anything from recessed features to simple stepped geometry.

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Disc
SAG Tool

Disc

Designed for flat, near-flat, and convex surfaces. The disc tool provides high contact area and efficient material removal. Ideal for large optical flats, die faces, and precision engineering surfaces.

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Drum
SAG Tool

Drum

Engineered for bores, internal channels, and cylindrical components. The drum geometry can maintain consistent SAG contact on internal and external rounded surfaces or flat side faces, where other tool types cannot operate.

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What SAG Does

Grinding and Polishing
in One Process

Shape Adaptive Grinding (SAG) combines surface grinding and precision polishing into a single process. Unlike rigid abrasive tools, SAG tooling conforms elastically to the workpiece. Maintaining consistent contact pressure across the surface, eliminating the dependency on operator skill and machine precision. The result is a faster, more repeatable surface finishing process with measurably lower scrap rates.

SAG polishing stages
Removing machining marksEliminates tool marks left by CNC milling or turning without altering part geometry.
Form correctionAchieve those tight surface form tolerances.
Achieving mirror surface finishesRa < 0.01μm achievable on metals and ceramics, including glass.
Reducing production cycle time & manual labourReplace hand-polishing with CNC polishing, for comparable cycle times to face-milling operations.
Eliminating part-specific toolingOne SAG tool covers a wide range of component profiles. No more bespoke fixtures required for each new part.
Reducing scrap ratesConsistent, controlled material removal reduces the risk of over-polishing or geometry deviation.
Improving process repeatabilityEvery part in a batch leaves the process to the same surface specification, removing the variation between operators and shifts.
Applications

Ideal for Complex
Surface Finishing

SAG tools can be utilised on a wide range of materials and geometries. Common applications include:

Complex CNC machined surfacesRemoving tool marks from milled or turned parts without re-fixture or changing geometric tolerance.
Medical implants and surgical instrumentsAchieving the surface cleanliness and roughness requirements for implant-grade titanium and cobalt-chrome components.
Mould & die finishingPolishing injection mould cavities, forging dies, and press tools to a mirror finish for improved part release quality and increasing tool life.
Metal additive manufacturing (3D printing)Post-process finishing to reduce surface roughness from Ra 10–20μm to Ra < 0.3μm for laser powder bed fusion (LPBF) and direct energy deposition (DED) parts.
High-value componentsAny component which is sensitive to high scrap rates or consistency between batches, e.g. aerospace turbine blades.
High-volume productionReducing manual operations and increasing cycle times for polishing processes.