Custom Form End Mill Replaces Three Tools and Saves $25,000 Annually
Why run three tools when one can handle the entire feature?
Fullerton designed a custom form end mill that combined three tools into one. The new design cut 26 minutes from the cycle, tripled tool life, and saved the customer $25,000 annually.
At a Glance
The Challenge
The customer was using three separate tools to machine a single part feature. Each tool brought another setup and tool change to the process.
That meant more time spent moving between steps, more opportunities for variation, and a longer overall cycle. The customer needed a simpler way to machine the feature — and a tool that could stay in the cut longer.
The Solution
Fullerton engineered a custom form end mill that combined the work of all three tools into a single design. Instead of running three tools in sequence, the customer could complete the entire feature with one tool. This eliminated the tool changes and setup time between operations while also creating a more consistent process.
The custom form end mill also delivered significantly longer tool life, reducing the frequency of tool replacements and keeping production moving.
Three tools in sequence became one tool in the cut.
The Results
Consolidating three tools into one made a noticeable difference:
- Three tools became one: The custom form end mill eliminated the extra tool changes and setup time.
- Cycle time dropped by 26 minutes: Less time between operations meant more time making parts.
- Tool life tripled: The customer could run longer before replacing the tool.
- Annual costs dropped by $25,000: Faster cycles and longer tool life delivered measurable savings.
One tool, 26 fewer minutes, and a much more efficient operation.
When Does Tool Consolidation Make Sense?
A custom form end mill may be worth evaluating when:
- One part feature requires multiple tools
- Tool changes are adding more time than the cut itself
- The current tooling isn't meeting tool-life goals
- Multiple setups are creating unwanted variation
- A high-volume application would benefit from a shorter cycle
If several tools are working together to create the same feature, there may be an opportunity to combine them into one custom solution.
Frequently Asked Questions
How much did the custom form end mill save annually? +−
The custom form end mill saved the customer $25,000 annually by replacing three tools, reducing cycle time by 26 minutes, and tripling tool life.
How many tools did the custom form end mill replace? +−
It replaced three separate tools with one custom form end mill.
How much did tool life improve? +−
Tool life tripled compared to the customer's previous tooling, significantly reducing how often tools needed to be replaced.
How much cycle time was saved? +−
The custom form end mill reduced cycle time by 26 minutes by combining three operations and eliminating the tool changes between them.
Several Tools Building One Feature?
Tell us about the feature and our engineering team will see if it can be formed with one tool.
