

Why
GRAPHITE?
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High Thermal and Electrical Conductivity
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Excellent Precision Machinability
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Consistent Purity and Chemical Resistance
Perfect For...
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EDM Electrodes & Tooling
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Battery Anodes & Conductive Coatings
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Aerospace, semiconductors, and Metallurgical
Synthetic Graphite & Carbon/Graphite Powders for Industry
BADGERADVANCED Graphite includes American Carbon’s full line of synthetic graphite products - ranging from large-format blocks and rounds to fine carbon and graphite powders used in advanced industrial applications. Our synthetic graphite is manufactured from high-purity petroleum coke through a high-temperature graphitization process, resulting in a dense, electrically conductive, and highly machinable material with excellent thermal resistance.
We supply bulk graphite in standard and custom dimensions for machining into crucibles, EDM electrodes, furnace components, and heat spreaders. In addition, we offer a wide range of carbonaceous powders - including milled synthetic graphite and amorphous carbon - in various particle sizes, purities, and morphologies. These powders are used in lubricants, battery anodes, conductive coatings, metal processing, and additive manufacturing.
Whether you require isotropic graphite for high-load machining or high-surface-area powders for energy storage or thermal interface applications, BADGERADVANCED Graphite delivers consistent performance and tailored material solutions.
Applications
BADGERADVANCED Graphite supports demanding applications across aerospace, energy, manufacturing, electronics, and thermal management industries. Whether delivered as large-format blocks or precision carbon powders, our graphite materials offer thermal stability, machinability, conductivity, and chemical resistance.
Our synthetic graphite blocks and rounds are available in raw, semi-machined, or fully machined form. These materials are used for high-temperature tooling such as furnace components, refractory molds, and pressing dies. In electrochemical systems, they serve as EDM electrodes, grounding plates, and plating conductors. In semiconductor and vacuum applications, fully machined parts are used as carrier components, insulators, and structural elements. Aerospace and defense customers rely on our graphite for rocket nozzles, shielding components, and custom-machined heat management parts. For customers with CNC or manual machining capabilities, we also offer no-waste block and round formats to minimize material loss.
Our graphite and carbon powders are engineered for a wide range of functional uses. In lubrication and coatings, they are used in dry lubricant compounds, anti-seize pastes, conductive coatings, and mold-release sprays. For battery applications, high-purity synthetic and flake graphite powders are used as anode material in lithium-ion cell production—where particle size, roundness, and purity are tightly controlled. Refractory and metallurgical customers use our powders as additives in crucibles, bricks, and casting molds to improve thermal performance and reduce slag formation. Graphite powders are also used in thermal interface materials (TIMs), EMI/RFI shielding pastes, and composite feedstocks for additive manufacturing.
Whether your application requires solid graphite precision components or carbon-based powders engineered for electrochemical or thermal performance, BADGERADVANCED Graphite delivers reliable, high-spec material solutions for industrial users.
Manufacturing Process
BADGERADVANCED Graphite products are manufactured using high-temperature processing and precision classification techniques to ensure consistent performance in structural, thermal, and electrochemical applications. Our synthetic graphite blocks begin as high-purity petroleum coke blended with coal tar pitch. This mixture is molded into green carbon blocks and then baked at approximately 1000 °C to solidify the structure. The blocks are subsequently graphitized in an inert environment at temperatures exceeding 2800 °C. This graphitization process produces a dense, crystalline synthetic graphite with exceptional electrical conductivity, machinability, and thermal resistance.
After graphitization, the blocks can be supplied as raw stock, semi-machined to size, or fully machined to meet exacting tolerances. Machined synthetic graphite is commonly used for EDM electrodes, crucibles, vacuum fixtures, and high-temperature tooling. Both standard-density and isotropic grades are available, with dimensional accuracy, grain uniformity, and ash content verified before shipment.
Graphite and carbon powders are produced through milling and classification of synthetic graphite, natural flake graphite, and amorphous carbon. These powders are processed using jet mills, attrition mills, or ball mills, depending on the desired particle shape and purity. For advanced applications, such as lithium-ion battery anodes or conductive pastes, we offer spheronized graphite, thermally purified powders, and surface-treated grades. Powder lots are tested for particle size distribution (D10/D50/D90), tap density, BET surface area, and elemental purity using ICP and LOI methods.
Our vertically integrated production approach ensures traceability and consistency from bulk graphite blocks to battery-grade graphite powders - tailored for performance across thermal management, electrical conductivity, chemical processing, and energy storage applications.
Specifications
BADGERADVANCED Graphite products are available in a range of grades, densities, and particle sizes to meet the performance requirements of structural, electrical, and thermal applications. Our synthetic graphite blocks are characterized by high purity, fine grain structure, and consistent bulk density—making them suitable for precision machining, EDM, and high-temperature processing. Graphite and carbon powders are classified by particle size distribution (D10/D50/D90), surface area, tap density, and chemical composition. Battery-grade graphite powders are available with controlled morphology and surface treatments to meet anode material specifications. All materials are tested to ensure compliance with ASTM and industry standards.
Our product technical data sheets are also available in PDF form. Please click below to download a PDF version of the data sheet.
Physical Properties | 50-100 Series | 50-200 Series | 50-300 Series | 50-400 Series | 50-500 Series |
|---|---|---|---|---|---|
Density (lb/in³) | ≥ 0.0569 | ≥ 0.0614 | ≥ 0.063 | ≥ 0.0646 | ≥ 0.0646 |
Maximum Particle Size (in) | 0.158 | 0.0787 | 0.0315 | 0.00177 | 0.0035 |
Porosity (%) | 15-17 | 15-17 | 15-17 | 13-15 | 12-14 |
Specific Resistance (μΩ•in) | ≤ 0.24 | ≤ 0.2 | ≤ 0.2 | ≤ 0.2 | ≤ 0.2 |
Bending Strength (psi) | ≥ 1,160 | ≥ 2,103 | ≥ 2,103 | ≥ 3,770 | ≥ 3,770 |
Compressive Strength (psi) | ≥ 3,915 | ≥ 4,641 | ≥ 5,340 | ≥ 7,977 | ≥ 7,977 |
C.T.E. (212-1112°F) (10⁻⁶/°F) | ≤ 1.7 | ≤ 1.4 | ≤ 1.6 | ≤ 1.6 | ≤ 1.7 |
Allowable Tolerance (in) | ± 0.08 | ± 0.08 | ± 0.08 | ± 0.08 | ± 0.08 |
Allowable Camber (%) | ≤ 0.5 | ≤ 0.5 | ≤ 0.5 | ≤ 0.5 | ≤ 0.5 |
Production Method | Extruded | Extruded | Molded | Molded | Isostatic Mold |
Physical Properties | 50-100 Series | 50-200 Series | 50-300 Series | 50-400 Series | 50-500 Series |
|---|---|---|---|---|---|
Density (g/cm³) | ≥ 1.58 | ≥ 1.70 | ≥ 1.74 | ≥ 1.79 | ≥ 1.80 |
Maximum Particle Size (mm) | 4 | 2 | 0.8 | 0.04 | 0.09 |
Porosity (%) | 15-17 | 15-17 | 15-17 | 13-15 | 12-14 |
Specific Resistance (μΩ•m) | ≤ 9.5 | ≤ 8 | ≤ 8 | ≤ 8 | ≤ 8 |
Bending Strength (mpa) | ≥ 8 | ≥ 14.5 | ≥ 14.5 | ≥ 26 | ≥ 26 |
Compressive Strength (mpa) | ≥ 27 | ≥ 32 | ≥ 36.8 | ≥ 55 | ≥ 55 |
C.T.E. (100-600°C) (10⁻⁶/°C) | ≤ 3.0 | ≤ 2.5 | ≤ 2.9 | ≤ 2.9 | ≤ 2.9 |
Allowable Tolerance (mm) | ± 2 | ± 2 | ± 2 | ± 2 | ± 2 mm |
Allowable Camber (%) | ≤ 0.5% | ≤ 0.5% | ≤ 0.5% | ≤ 0.5% | ≤ 0.5% |
Production Method | Extruded | Extruded | Molded | Molded | Isostatic Mold |
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