Tool and Die makers are among the most highly skilled workers in
manufacturing. These workers produce tools, dies, and special guiding
and holding devices that enable machines to manufacture a variety of
products we use daily, from clothing and furniture to heavy equipment
and parts for aircraft.
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 (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 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 machining properties like
hardness and heat tolerance, of a wide variety of common metals and
alloys. As a result, tool and die makers are skilled in machining
operations, mathematics, and blueprint reading. In fact, tool and die
makers often are considered highly specialised machinists. The main
difference between tool and die makers and machinists is that machinists
normally make a single part during the production process, while tool
and die makers make parts and machines used in the production process.
Working from blueprints, tool and die makers must first plan the
sequence of operations necessary to manufacture the tool or die. Next,
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 like filing, grinding, and polishing surfaces.
How Toolmakers Work
Modern technology has changed the ways in which tool and die makers
perform their jobs. Today, for example, these workers often use
computer-aided design (CAD) to develop products and parts.
Specifications entered into computer programs can be used to
electronically develop drawings for the required tools and dies.
Numerical tool and process control programmers use computer-aided
manufacturing (CAM) programs to convert electronic drawings into
computer programs that contain instructions for a sequence of cutting
tool operations. 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; however, tool and
die makers are 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 (CMM), which use software and sensor arms 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, the
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.
Tool and die makers usually work in toolrooms. These areas are quieter
than the production floor because there are fewer machines in use at one
time. They also are generally kept clean and cool to minimize
heat-related expansion of metal workpieces and to accommodate the
growing number of computer-operated machines. To minimize the exposure
of workers to moving parts, machines have guards and shields. Most
computer-controlled machines are totally enclosed, minimizing the
exposure of workers to noise, dust, and the lubricants used to cool
workpieces during machining. Tool and die makers must also 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.