Tool and die makers are among the most highly skilled workers in manufacturing. These workers produce and repair tools, dies, and special guiding and holding devices that enable machines to produce a variety of products we use daily—from clothing and furniture to heavy equipment and parts for aircraft. They may work in manufacturing plants that produce tools in house, or in machine shops that only produce specialized machine tools for other manufacturers.
Toolmakers craft precision tools and machines that are used to cut, shape, and form metal and other materials. They also produce jigs and fixtures—devices that hold metal while it is bored, stamped, or drilled—and gauges and other measuring devices. Die makers construct metal forms, called dies, that are used to shape metal in stamping and forging operations. They also make metal molds for diecasting and for molding plastics, ceramics, and composite materials. Some tool and die makers craft prototypes of parts, and then, working with engineers and designers, determine how best to manufacture the part. In addition to developing, designing, and producing new tools and dies, these workers also may repair worn or damaged tools, dies, gauges, jigs, and fixtures.
To perform these functions, tool and die makers employ many types of machine tools and precision measuring instruments. They also must be familiar with the machining properties, such as hardness and heat tolerance of a wide variety of common metals, alloys, plastics, ceramics, and other composite materials. Tool and die makers are knowledgeable in machining operations, mathematics, and blueprint reading. In fact, tool and die makers often are considered highly specialized machinists. Machinists typically produce less elaborate parts for machinery, while tool and die makers craft very durable, complex machine tools. As a result, tool and die makers must have a general understanding of the mechanics of machinery. (See the section on machinists elsewhere in the Handbook.)
While many tools and dies are designed by engineers or tool designers, tool and die makers are also trained to design tools and often do. They may travel to a customer's plant to observe the operation and suggest ways in which a new tool could improve the manufacturing process.
Once a tool or die is designed, tool and die makers, working from blueprints, plan the sequence of operations necessary to manufacture the tool or die. They measure and mark the pieces of metal that will be cut to form parts of the final product. At this point, tool and die makers cut, drill, or bore the part as required, checking to ensure that the final product meets specifications. Finally, these workers assemble the parts and perform finishing jobs, such as filing, grinding, and polishing surfaces. While manual machining has declined, it is still used for unique parts and sharpening of used tools.
Many tool and die makers use computer-aided design (CAD) to develop products and parts. Specifications entered into computer programs can be used to electronically develop blueprints for the required tools and dies. Numerical tool and process control programmers use CAD or computer-aided manufacturing (CAM) programs to convert electronic drawings into CAM-based computer programs that contain instructions for a sequence of cutting tool operations. (See the section on computer control programmers and operators elsewhere in the Handbook.) Once these programs are developed, computer numerically controlled (CNC) machines follow the set of instructions contained in the program to produce the part. Computer-controlled machine tool operators or machinists normally operate CNC machines, but tool and die makers are often trained in both operating CNC machines and writing CNC programs; and they may perform either task. CNC programs are stored electronically for future use, saving time and increasing worker productivity.
After machining the parts, tool and die makers carefully check the accuracy of the parts using many tools, including coordinate measuring machines, which use sensor arms and software to compare the dimensions of the part to electronic blueprints. Next, they assemble the different parts into a functioning machine. They file, grind, shim, and adjust the different parts to properly fit them together. Finally, tool and die makers set up a test run, using the tools or dies they have made to make sure that the manufactured parts meet specifications. If problems occur, they compensate by adjusting the tools or dies.
Working Conditions
Tool and die makers may either work in toolrooms or manufacturing production floors. Toolrooms are generally kept clean and cool to minimize heat-related expansion of metal workpiece, while specialty machine shops have a factory floor covered with machinery. To minimize the exposure of workers to moving parts, machines have guards and shields. Most computer-controlled machines are totally enclosed, minimizing workers' exposure to noise, dust, and the lubricants used to cool workpieces during machining. Working around this machinery can still be dangerous, so tool and die makers must follow safety rules and wear protective equipment, such as safety glasses to shield against bits of flying metal, earplugs to protect against noise, and gloves and masks to reduce exposure to hazardous lubricants and cleaners. These workers also need stamina, because they often spend much of the day on their feet and may do moderately heavy lifting. Companies employing tool and die makers have traditionally operated only one shift per day. Overtime and weekend work are common, especially during peak production periods.
