Non-standard Customised Tools

Key Features:
1. Full Customization
– Geometry: Design unique tool shapes (e.g., asymmetric profiles, hybrid flutes) for specialized grooves, threads, or contours.
– Cutting Edges: Custom edge microgeometry (honing, chamfers, or micro-texturing) to optimize chip control, reduce cutting forces, or improve surface finish.
– Shank Integration: Tailored shank dimensions and coolant channels to fit non-standard toolholders or CNC machines.

2. Material Innovation
– Substrate Options: Tungsten carbide (WC-Co), CBN, PCD, or ceramic composites, tailored for hardness, toughness, or thermal resistance.
– Coatings: Proprietary PVD/CVD coatings (e.g., AlTiN, TiSiN, DLC) optimized for high-speed machining, dry cutting, or corrosive environments.

3. Application-Driven Design – Complex Workpieces: Tools for deep cavities, thin-walled parts, or interrupted cuts requiring extreme rigidity and vibration damping.
– Exotic Materials: Solutions for machining Inconel, titanium aluminide, CFRP, ceramics, or hardened steels (up to 70 HRC).
– Micro-Machining: Miniature tools (down to Ø0.1 mm) for medical implants, electronics, or optical components.

4. Technical Collaboration
– Engineering Support: Co-design tools with CAD/CAM simulations, stress analysis, and prototyping.
– Testing & Validation: On-site or lab trials to verify tool performance under real-world conditions.

Benefits:
– Solve Unique Challenges: Overcome limitations of standard tools with designs tailored to your specific material, machine, and application.
– Maximize Efficiency: Optimized tools reduce cycle times, minimize scrap, and extend tool life in niche operations.
– Cost Savings: Lower per-part costs through reduced downtime, higher feed rates, and extended tool longevity.
– Future-Proof Solutions: Adapt tools for evolving production needs, including new materials or complex geometries.
– End-to-End Support: From concept to production, backed by technical expertise and rapid prototyping services.

Customization Options:
– Geometry: Asymmetric flutes, variable helix angles, or multi-diameter profiles.
– Edge Preparation: Custom honing, T-lands, or polished edges for burr-free finishes.
– Coatings: Multi-layer, nano-composite, or lubricious coatings for specific wear resistance or thermal barriers.
– Coolant Systems: Internal channels, through-tool coolant, or specialized nozzle integration.
– Material Grades: Substrates with additives (TaC, NbC) for enhanced heat resistance or fracture toughness.

Quality Assurance:
– Precision Manufacturing: CNC grinding and EDM processes ensure tolerances ≤ ±0.005 mm.
– Rigorous Testing: Performance validation for tool life, surface finish, and stability under load.
– Certifications: ISO 9001 compliance with full traceability of materials and processes.
– Batch Consistency: Statistical process control (SPC) guarantees repeatability in mass production.

Packaging & Logistics:
– Protective Packaging: Custom foam inserts, vacuum sealing, or anti-corrosion treatments for delicate tools.
– Flexible Quantities: Prototype batches (1–10 units) to high-volume production (1,000+ units).
– Lead Time: 3–8 weeks (depending on design complexity and material availability).

Industry Applications:
– Aerospace: Turbine blade root machining, honeycomb structure milling, CFRP drilling.
– Medical: Micro-threading for implants, bone screw grooves, surgical instrument profiling.
– Automotive: EV battery cell machining, lightweight alloy components, hardened gear cutting.
– Energy: Deep-hole drilling for oil/gas tooling, turbine blade cooling channel reaming.
– Electronics: Micro-drilling PCBs, connector pin machining, optical lens contouring.

Customization Workflow:
1. Requirement Analysis: Define material, machine specs, tolerances, and production goals.
2. Design & Simulation: CAD modeling, FEM stress analysis, and virtual machining trials.
3. Prototyping: Produce and test functional prototypes to validate performance.
4. Production & QC: Full-scale manufacturing with rigorous quality checks.
5. Post-Sales Support: Tool life monitoring, regrinding services, and iterative optimization.

Non-Standard Customized Tools bridge the gap between conventional tooling and the most demanding production challenges. Whether machining next-generation materials, achieving micron-level precision, or optimizing high-volume workflows, these tools empower innovation and efficiency.