As high-speed machining and milling becomes more popular, moldmakers are looking for alternatives to their traditional low-speed toolholders.

The need to maximize machine utilization and capability is a constantly increasing one. Modern machine tools with spindle speeds of 60,000 to 80,000 rpm represent real opportunity to achieve those goals, and are a big part of the ability to achieve high-speed machining (HSM). The definition of HSM has been evolving and can include a combination of factors such as cutting speed, spindle speed and federates; however, it is commonly defined as light depth-of-cut machining at or above 15,000 rpm, or greater than 1,000 feet per minute, depending on cutter diameter. But, lightning-fast spindle speeds and table speeds are just one part of the equation. In order to shift into HSM, manufacturers also need to take a hard look at cutting tools, toolholding and good old-fashioned application expertise.

Cutting tool challenges such as the ability to avoid chatter, deflection and minimize runout are equally determined by the rigidity, concentricity and balance of the toolholder. There are numerous choices for toolholding, and no one set answer for all applications. Among these are collet style, those that use a (arbor) set-screw, hydraulic holders and of course thermal shrink style. When considering HSM, balanced tooling is a must, and the highest amount of natural balance possible only serves to help the overall cause. Collet chucks are acceptable, but only if they are precision ground to avoid natural run-out.

Among all of the toolholding choices, thermal shrink fit stands alone above the rest as the most accurate and rigid, making it the best choice for max rpm HSM applications. Shrink-fit systems consist of a machine with a thermal induction coil and a choice of cooling station configurations, and a range of special holders that can shrink and ‘unshrink’ a virtually unlimited number of times. The process focuses heat to the nose of the holder to expand the inside diameter of the holder and allow the cutting tool of choice to slip inside. As the nose cools, it contracts and becomes one with the tool. Balancing and presetting also can be accomplished. Unlike any other method of holding, shrink fit allows the highest torque transfer, accuracy of 3 micron at a 3X length to diameter ratio and flexibility to reach areas where other tools would simply be impractical.

Thermal shrink fit systems like the one above the greatest level of rigidity and accuracy between holder and cutting tool making them an ideal choice for HSM applications. Images courtesy of Seco-Carboloy.

Identifying specific areas where CAM software can utilize machine capabilities to benefit the user and maximize milling machine potential.

Sustainable, productivity-boosting innovations for moldmakers, including stress relief, traceability and cooling solutions.

After attending IMTS, it's clear that the integration of advanced technologies is ready to enhance precision, efficiency and automation in mold manufacturing processes. It’s a massive event, so here’s a glimpse of what the MMT team experienced firsthand.

All Aspects Approach The last leg of the stool is still grey matter. The significant advancements in machine tools, cutting tools and toolholding all still require the proper evaluation, selection and application that can be done by experienced machinists and application engineers. So, before you rev up the spindle, consult with your machinists and application specialists to ensure a safe and productive operation.

When used for conformal cooling in plastic injection, 3D printing opens a wide range of design freedom. This design freedom enables designers to develop highly-efficient thermal regulation networks. However, this blessing also comes at the expense of not only higher manufacturing cost but also higher design cost as the designer could spend weeks to develop optimal cooling channels. This webinar will explore strategies and tools — including SimForm, a front-end thermal simulation app — to help tool designers and tooling managers maximize the benefits of 3D printing while minimizing manufacturing and design costs. Agenda: 3D printing applied to the plastic injection industry 3D printing pros and cons Tools and methods to facilitate the integration of 3D printing

Identifying specific areas where CAM software can utilize machine capabilities to benefit the user and maximize milling machine potential.

The concept of precision cutting tools for HSM also has been adapted to meet the growing needs of very small applications and tight-tolerance inside diameter holes. To address these application areas a moldmaker should choose from a range of fine boring tools for precision internal machining applications in diameters from .012 inches to .315 inches. The connection technology in such tools is used for low runout and high part finish quality.

The Manufacturing Technology Series East, featuring EASTEC in West Springfield, Massachusetts — is at the epicenter of a region that is a traditional manufacturing powerhouse. Historically, more than 700 companies have connected at this event to network, learn from industry experts and explore the latest manufacturing technologies.

Discover how to enhance your mold design process with the right CAD/CAM tool for parting and cavity design. This webinar will explore CAD/CAM capabilities including how hybrid solid/surface modeling can streamline workflow and improve accuracy. Learn how to confidently tackle parting, runoff, and shutoff, ensuring precision and efficiency in your designs. Agenda: Part analysis QuickSplit techniques Parting and runoff strategies Shutoff solutions

To complement the range of boring tools, an axial type fine boring head provides micrometer adjustments in increments of .0004 inches and vernier adjustments of .0001 inches on bore diameter. Precision manufacturing and super-fine adjustments permit operating speeds of up to 30,000 rpm / 4,920 sfm. The development of such tools further reinforces the importance of precision—both in the tool and the holding device.

Survey findings reveal a shortage of skilled mold designers and engineers in the moldmaking community, calling for intervention through educational programs and exploration of training alternatives while seeking input from those who have addressed the issue successfully.

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The Society of Plastics Engineers’ Mold Technologies division is accepting applications for a $3,000 student scholarship honoring Joseph Prischak and a $5,000 educational grant program.

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MoldMaking Technology addresses the complete lifecycle of the manufacture and maintenance of a mold—from design to first shot—by providing solutions and strategies to moldmaking professionals charged with designing, building and repairing molds. About Us

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Mark the calendar for AMBA Conference 2025, "Breakthrough Innovation," May 7-9, 2025, Grand Rapids, MI. During this industry event, attendees will meet with peers to discuss best practices in business, employee management, technology and more.

With machine tool capability a given, and the proper choice of cutting tool and toolholder being made, HSM is a snap, right? Not exactly. Particular focus must be given to the assembly of tool and holder. The fact that each may be inherently balanced doesn’t translate into them being balanced as an assembly. Balancing must therefore be done after the tool and holder are connected. That holds true for whatever combination you choose, and is really a key to effective and efficient machining even in lower speed, heavier cut applications, but ultimately critical for HSM.

Join MoldMaking Technology Editorial Director Christina Fuges as she discovers the benefits of eLearning, including promoting sustainability in moldmaking by reducing travel, minimizing waste and enhancing global workforce accessibility.

A discussion with AMT’s Bill Herman during ShopTalk on the big stage at IMTS 2024 highlights moldmaking's unique blend of craft and technology that is driving innovation while its community tackles key challenges.

Join MoldMaking Technology Editorial Director Christina Fuges as she discovers the benefits of eLearning, including promoting sustainability in moldmaking by reducing travel, minimizing waste and enhancing global workforce accessibility.

This fine boring head is pre-balanced to 30,000 rpm out of the box and features precision adjustments for best machining with the range of solid tooling (all with the same shank size).

Alba Enterprises created a mold base to match the needs and pacing of product iteration using mold tooling made via additive manufacturing.

Debuting in 2010, the Parts Cleaning Conference is the leading and most trusted manufacturing and industrial parts cleaning forum focused solely on delivering quality technical information in the specialized field of machined parts cleansing. Providing guidance and training to understand the recognized sets of standards for industrial cleaning, every year the Conference showcases industry experts who present educational sessions on the latest and most pressing topics affecting manufacturing facilities today.  Discover all that the 2025 Parts Cleaning Conference has to offer!

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For 40+ years, Dynamic Tool Corp. has offered precision tooling, emphasizing education, mentoring and innovation. The company is committed to excellence, integrity, safety and customer service, as well as inspiring growth and quality in manufacturing.

While the transition from traditional methods to this innovative approach may present initial challenges, the benefits far outweigh the learning curve. Through the NextMold and partner network, Forward AM provides comprehensive support at every stage of the integration process. This ensures a smooth adoption of the technology into company’s operations, including seamless collaboration with molding companies. Forward AM’s commitment is to facilitate this technological transformation, enabling your business to leverage the full potential of 3D-printed mold inserts. Agenda:  Molding with 3D-printed inserts Ultrasim3D Next Mold: Forward AM offering Successful adaption: integration at Beaumont Technologies

On June 25-27, 2024, RAPID + TCT returned to the West Coast for the first time in nearly a decade! The three-day event featured the latest in 3D-printing technology from the industry’s leading product and service providers, a full schedule of speakers including a keynote series, and over 125 hours of educational content. The expansive show floor showcased over 400 exhibiting companies’ latest advancements. And next year? It will be even better! Start planning your trip to Detroit, MI to experience North America’s largest additive manufacturing and industrial 3D printing event in 2025!

There has been much debate about the different taper types, and arguments can be made for each as they all have their strengths. Judging a back-end solely on repeatability, weight and capability for high speed, would lead us to accept that HSK is the most ideally suited for HSM; however, this can change depending on shop conditions and several other factors, so all must be considered during evaluation.

A combination of lasers, probes and software help moldmakers automate in-process cutting tool and workpiece measurement.

Extrusion's general sessions cover best practices, troubleshooting and processing solutions that can help you run your operation and maximize the utilization of your existing assets—as efficiently as possible. ​ Extrusion professionals from the shop floor to the front office are represented at the Extrusion Conference.​ You’ll meet the entire global supply chain: manufacturing managers, supervisors, engineers and technicians, as well as engineers and technical managers at OEMs and other firms.

In this most recent product roundup, MMT continues to offer a variety of innovative as well as tried-and-true technologies to benefit moldmakers.

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PTXPO 2025 is a comprehensive showcase of cutting-edge technologies and innovations within the plastics molding industry. Join fellow molders, moldmakers, brand owners, OEMs and their full suite of suppliers in Rosemont, IL for three days of non-stop networking, education and business development opportunities.

After attending IMTS, it's clear that the integration of advanced technologies is ready to enhance precision, efficiency and automation in mold manufacturing processes. It’s a massive event, so here’s a glimpse of what the MMT team experienced firsthand.

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Since cutting tools wear at varying rates during the machining process, manufacturers have to know the usable lifecycle—the point at which the cutting tool needs to be indexed, reground or replaced depending on the style of tool. Knowing and understanding predictable tool life helps shops make the most out of their cutting tools and, more importantly, get the most from the plant floor.

Intralox's integration of the Alpha Laser ALFlak has significantly improved their tool room efficiency when it comes to difficult welds and urgent repairs.

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For example, when looking at “D Type” collets (precision ground all over), you get completely static clamping, meaning it will not expand at high rpm. In contrast, if you were to use ER collets, there is a larger natural runout and as rpm rises, your clamping will actually decrease as centrifugal forces cause the collet to naturally open slightly.

To produce fine finishes and maintain long and predictable tool life while performing high-speed applications, you must run balanced tooling. Part of understanding the balance issue is knowing what the maximum “un-balance” your machine can withstand. As a general rule of thumb, it is accepted that a maximum of 3 grams per millimeter of unbalance is permitted in HSM toolholders. But, at very high spindle speeds (30,000+ rpm); it is not uncommon to require closer to just 1 gram per millimeter. This can be compared to a standard, generic endmill holder, which can have as much 250 grams per millimeter unbalance. Depending on the actual rpm used, this can be the difference between catastrophic failure and complete success. Balanced tooling will yield better results at any rpm, but becomes an absolute necessity when considering HSM, having the ultimate impact on productivity, quality, consistency, predictability and safety.

Join this webinar where Hexagon will explore how state-of-the-art CAD/CAM technology can drive your business forward. Learn how to optimize tool paths, enhance design accuracy and reduce lead times with advanced simulation. Discover the power of automation and real-time data for continuous improvement. Tailored for mold and die manufacturers, this session offers actionable insights to boost productivity and quality. Don’t miss this opportunity to gain a competitive edge in progressive die manufacturing. Agenda:  Key challenges in progressive die manufacturing Optimizing tool paths Enhancing mold and die design accuracy Reducing lead times with simulation Automating processes for greater efficiency Leveraging real-time data for continuous improvement

Many HSM applications are performed in the manufacture of molds and dies, using a variety of endmills. Enclosed pocket, cavity milling, and mold and die machining are all essentially synonymous and place heavy demand on the ability for machine tools to machine in multiple dimensions. Common operations include roughing, semi-finishing and finishing, with finishing being the most time consuming, requiring as much as 90 percent of the whole process. Advancements in cutting tools and the further development and use of HSM have allowed manufacturers to significantly reduce the overall manufacturing time, all but eliminating the need for handwork. True vertical wall machining also has been made possible through the development of 120-degree ballnose cutters that can effectively machine both down and up, further reducing machine cycle times.

*All prices are Manufacturers Suggested Retail Prices (MSRP). MSRP excludes installation (except if factory-installed), taxes and other costs, and is subject to change without prior notice. Dealer sets actual price. [Pictures are for informational purposes only.]

In ISO 9001 quality management systems, the Management Representative (MR) plays a crucial role. While the 2015 version of ISO 9001 no longer mandates this position, having a trusted management member serve as an MR remains vital for streamlining operations and maintaining quality standards.

To permit for these maximum rpm applications, cutting tools have to be precise and long lasting, or more accurately, predictable, especially in unmanned operations. They also have to be capable of holding tolerance at these high speeds, and resist deflection and vibration especially in applications with longer overhangs. Balance, edge preparation, geometry and cutting tool (edge) material or grade all contribute to precision and life. Different tool shank materials also are to be considered and include steel, Densimet and carbide, with carbide being the most rigid.

ReelView Fishing faced an electronics obstacle in the development of its new technology for underwater video. Additive manufacturing for moldmaking enabled the speed necessary to iterate to a solution.

Hydraulic chucks offer excellent transmittable torque and near perfect concentricity, so this style is an ideal choice with only one drawback—the units can be relatively bulky and can limit practical use in certain applications.

Presentations will cover 3D printing for mold tooling, material innovation, product development, bridge production and full-scale, high-volume additive manufacturing.

HSM will continue to have a major impact on productivity and profitability across many markets like mold and die, but also automotive and aerospace. From very soft metals and non-metals to 60RC+ die steel, the success of many shops will hinge on HSM capability. And those that practice an ‘all-aspects’ process—including the machine, cutting tool, toolholder, proper balance and application support—will thrive.

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These humble but essential fasteners used in injection molds are known by various names and used for a number of purposes.

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Report analyzes moldmaking trends, pricing, labor shortages, capital costs, competitiveness strategies and construction spending challenges.

Mold shops will thrive if they practice an ‘all-aspects’ process to HSM, which includes the machine, cutting tool, toolholder, proper balance and application support.

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Discover how to enhance your mold design process with CAD/CAM software specifically tailored for the moldmaking industry. In part two of this webinar series, Cimatron will demonstrate how to intelligently design mold components, such as slides and lifters, using powerful CAD/CAM tools to accelerate the design process. Additionally, it will cover how to avoid errors and ensure design accuracy for ejector pins by checking clearance distances, calculating cutoff heights correctly, and thoroughly documenting all ejector components. Agenda: Slides Lifters Inserts Ejection pins and charts