Tool and Die Making

 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.