Inside RADO's High-Tech Ceramic Process at Comadur

by Brent Robillard

The Powerhouse Behind RADO’s Revolutionary Materials

When it comes to materials innovation in the world of watchmaking, few names resonate quite like Comadur—a Swatch Group company that stands as the beating heart of RADO’s groundbreaking high-tech ceramic watches. With over 1,300 employees across seven Swiss facilities, Comadur is not only one of the most important ceramic producers in horology, it’s also a quietly brilliant engine of material science in the luxury sector.

Comadur’s crowning achievement? Its mastery of high-tech ceramic, a material that’s ten times harder than stainless steel, yet surprisingly lightweight, hypoallergenic, and capable of being produced in a stunning range of finishes and colours.

Comadur RADO High-Tech Ceramic Process — ^{RADO builds its High-Tech Ceramic watches at the Comadur facility in Boncourt, Switzerland @calibre321}

As you can imagine, our team from The Calibrated Wrist felt very privileged when we were offered a tour of the Boncourt facilities, during Watches and Wonders this year—a visit normally reserved for brand ambassadors and VIPs. Understandably, both RADO and Comadur are protective of the technology behind their legacy. Photography and video are forbidden in most areas of production.

But, I can tell you that what we saw was nothing short of marvelous, and it solidified our respect for the innovation and technological prowess of the Comadur-RADO alliance.

Let’s take a closer look at how Comadur transforms raw powders into some of the most advanced watch cases and components in the world.

RADO: A Legacy of Innovation

The story begins in 1986, when RADO unveiled the Integral—the world’s first watch to incorporate high-tech ceramic. It was a bold statement, one that marked the beginning of a legacy centered around futuristic materials. Since then, ceramic has become synonymous with the brand. And behind every RADO ceramic watch lies Comadur’s sophisticated, multi-stage manufacturing process—combining material science with watchmaking precision.

Two Paths, One Vision: Pressing and Injection Moulding

Comadur manufactures ceramic components via two primary methods: traditional pressing, and more advanced injection moulding. Both methods require rigorous precision and allow for different design complexities, depending on the end product.

However, the core process remains consistent—an intricate sequence of mixing, shaping, refining, and finishing that transforms humble raw materials into lustrous, virtually indestructible watch parts.

The Stages of High-Tech Ceramic Production

Mixing

The process begins with the ultra-precise measurement of raw materials—down to the millionth. These are blended in a rotating tumbler with ceramic balls, forming a homogeneous slurry. From there, the slurry is transferred to a spray dryer, where it’s atomized and dried back into a fine powder, forming microdroplets. These are then processed into a paste and extruded into spaghetti-like strands, which are chopped into uniform “fitstock” pellets—the base feed material for injection. This process alone can take up to four days, and is completed in small batches.

Injection Moulding

The fitstock is reheated into a liquid and injected into steel moulds—each weighing up to 200 kg and engineered to withstand immense pressure. Every individual watch component has a dedicated mould, which is roughly 25% larger than the final part, to account for shrinkage during later steps. Injection moulding allows for the creation of complex geometries that would be difficult or impossible to achieve through conventional ceramic pressing.

Binder Removal (Debinding)

During mixing, organic binders are added to give the material flexibility for shaping. These are now carefully removed, typically through heat or chemical treatment, in a process that maintains the component’s integrity while prepping it for densification.

Sintering

This is where ceramic truly earns its strength. The parts are heated to 1,450°C—in ovens dedicated to each specific colour, since even the subtlest temperature shift can affect hue and finish. The sintering phase takes several days and causes the ceramic to shrink by approximately 25%, as it densifies and achieves its final hardness.

Machining

After sintering, the now-solid ceramic is machined to exacting tolerances using diamond-tipped tools—the only material hard enough to shape it. This phase can take up to an hour per component, depending on complexity, and ensures the precision required for high-end watchmaking.

Polishing & Sandblasting

Even matte-finished ceramics begin their life as high-gloss components. Each piece is placed into vats filled with vibrating ceramic media and polished for up to a full week. If a matte or satin finish is desired, parts are lightly sandblasted afterward to reduce reflectivity and achieve the final texture.

Washing

After polishing, the parts are washed mechanically for approximately an hour to remove any polishing compounds or particulates, ensuring they’re ready for assembly or further treatment.

Engraving

RADO uses lasers to etch numbers and markings onto the bezel, case, and bracelet. This ensures consistency in depth and precision in outlining.

The Plasma Oven

For select watches, there is an extra, extraordinary step: the plasma ceramic transformation.

Parts destined for this treatment are placed in one of Comadur’s three plasma ovens—of which only ten exist worldwide. Inside, the ceramic is exposed to temperatures exceeding 20,000°C (that’s almost four times hotter than the surface of the sun) and bombarded with a mix of gases that include argon and hydrogen.

This atmospheric cocktail strips away oxygen atoms, chemically altering the ceramic to deliver its grey colouring, while giving the surface a metallic sheen—without any actual metal content. The result is a rich, lustrous finish with the same hypoallergenic and scratch-resistant properties of traditional ceramic. The plasma oven, glowing with a surreal purple flame, looks like something out of science fiction—and in a way, it is.

Laquage and Quality Control

The final stages of RADO’s high-tech ceramic watch production involve the dextrous work of individual watchmakers. First, to fill the tiny voids left by lasers with a specialized lacquer which forms a permanent bond with the ceramic. And lasty, to perform a demanding final inspection and testing that ensures each timepiece meets with RADO’s exacting standards.

The Result: Timeless Beauty

From start to finish, the production of high-tech ceramic watch components at Comadur takes weeks, if not months. But the result is nothing short of extraordinary: ultra-durable, incredibly smooth, and endlessly versatile components that define what modern luxury can look and feel like.

Through this fusion of Swiss engineering, materials science, and aesthetic vision, Comadur ensures that every RADO ceramic watch isn’t just a timepiece—it’s a technological marvel that will last a lifetime (and the next).