by Bernard Martin

When you're cutting non-ferrous materials or composite stacks, you know that tool life, edge life, and surface finish can make or break a job. That’s where Mapal PCD tooling really shines. Known for precision, longevity, and optimized performance in high-speed applications, Mapal ’s polycrystalline diamond (PCD) solutions are engineered for shops that can’t afford to cut corners—or stop production for frequent tool changes.

Whether you're machining aluminum components for aerospace, carbon-reinforced plastics for automotive, or copper alloys for energy systems, Mapal delivers tools that stay sharp and consistent.

Why PCD?
PCD (Polycrystalline Diamond) is sintered diamond grit bonded with a metallic matrix, creating an ultra-hard cutting material ideal for abrasive and non-ferrous workpieces.

Compared to carbide, PCD offers up to 100x longer tool life in the right application—and dramatically reduces built-up edge and microburr formation, which saves time on post-processing.

Mapal’s PCD Tooling Range
Mapal offers a comprehensive selection of PCD tooling to suit everything from drilling and reaming to milling and contouring. Here's what you can expect:

PCD Milling Tools

• Applications: Face milling, slotting, shoulder milling, and contour milling of aluminum alloys, magnesium, and CFRP/GFRP.
• Sizes: Diameter ranges from Ø3 mm up to Ø200 mm depending on tool style.
• Designs: Monoblock, brazed, and replaceable-head versions.
• Tolerance: Down to ±0.01 mm on diameter, and exceptionally high surface finish capability (Ra < 0.4 µm with optimized parameters).
  

PCD Drills

• Applications: Precision drilling in aluminum engine blocks, transmission housings, and battery components.
• Geometry: Special flute geometries for optimized chip evacuation and reduced built-up edge.
• Diameter Range: From Ø3 mm up to Ø32 mm standard, with custom options available.
• Coolant Options: Internal through-coolant options for high-volume chip control.

PCD Reamers

• Applications: High-precision hole sizing in aerospace and automotive components.
• Tolerances: H6 and tighter, ensuring precise fits in critical assemblies.
• Designs: Fixed blade and adjustable reamers, with step reaming options for multi-diameter holes.

PCD Combination Tools

• For multi-step operations in a single pass—ideal for automated production lines where cycle time is critical.
• Custom-engineered based on your component specs, material, and machine interface.

Coatings and Edge Treatments
While PCD is itself the cutting edge, Mapal adds proprietary treatments to improve chip flow, reduce friction, and prevent delamination when working with layered composites. Edges can be honed or laser-cut for ultimate sharpness and consistency.

Reconditioning & Regrinding
One of the benefits of Mapal's PCD tooling is that many tools can be professionally reconditioned multiple timeswithout sacrificing performance. This significantly extends your ROI and keeps your tooling inventory lean.

Ready to Upgrade Your Tooling?
If you're cutting aluminum, magnesium, CFRP, or other non-ferrous materials, Mapals PCD tooling might be the last upgrade you need for a long while. Factory Tooling Solutions can help you spec out the right geometry, holder style, and chipbreaker for your application—and even set you up with a test tool to see the difference in action.

Let’s talk about how PCD can eliminate headaches and boost your output.

by Bernard Martin

If you've ever battled the heat barrier while cutting hard materials like cast iron or nickel-based alloys, you know the pain—tool wear skyrockets, inserts crater, and productivity tanks. But that’s where Greenleaf’s WG-700 Ceramic Insertscome into play. These are not your average ceramics. Built from whisker-reinforced ceramic material, WG-700 inserts are purpose-built for extreme conditions in high-speed turning and hard machining.

WG-700 inserts allow you to push surface speeds up to 5000 SFM without coolant—minimizing heat damage and maximizing tool life. Whether you're cutting aerospace alloys or gray cast iron, these inserts are your ticket to more uptime and higher throughput.

Built for Heat, Speed, and Tough Materials
WG-700’s secret weapon is its silicon carbide whisker reinforcement. Think of it like rebar inside concrete—it boosts fracture resistance while keeping the edge sharp under pressure. This makes WG-700 perfect for high-temp materials and hard metals, especially where coolant use is limited or not feasible.

Edge Prep & Chip Control Options
Greenleaf offers a variety of edge preps including T-land, honed, and sharp edge finishes. If you're roughing hard parts or taking heavy interrupted cuts, go for the honed edge. Finishing tight-tolerance features on aerospace alloys? The sharp edge prep gives you precision with less built-up edge.

And remember, while ceramic inserts may require a different approach than carbide, the productivity payoffs—especially in dry machining—are well worth it.

You'll find WG-700 delivering exceptional performance in dry turning of:

• Inconel, Waspaloy, and other nickel-based superalloys
• Hardened steels up to 62 HRc
• Gray and ductile cast iron
• Interrupted cuts on tough materials

With WG-700, you can reduce cycle times and tool changes, even in the most demanding conditions.

Get Started with Factory Tooling Solutions
Looking to reduce tool changes, cut cycle times, and boost performance on high-temp alloys? Reach out to Factory Tooling Solutions today. We’ll help you select the right WG-700 insert geometry and edge prep for your application—and even arrange a test run. Let's see what these ceramics can really do on your machines.

by Bernard Martin

When tight tolerances and micro-machining precision matter, Dümmel delivers. Known for their ultra-precise grooving and parting-off tools, Dümmel’s Minicut series shines as a comprehensive solution for small-part turning, especially in Swiss-type machining and micro-component production. Imported exclusively in North America by Everede Tool, this German-engineered product line is available to customers across the FTS territory.

Built for Precision – Designed for Performance
The Minicut series offers a wide range of tools built around precision ground solid carbide blanks, optimized for rigidity, repeatability, and edge stability. These tools excel in applications involving high-volume production and materials that challenge insert life and surface finish.

From grooving and cut-off operations to ID and OD turning, the Dümmel Minicut line is engineered for clean results, even at sub-millimeter widths. You’ll find cutting widths starting as small as 0.5 mm, making them ideal for fine-feature work on small parts.

Key Product Highlights

• Grooving and Cut-Off Tools - Minicut offers fixed-width grooving tools from 0.5 mm to 4 mm with several geometries optimized for stainless steel, titanium, aluminum, and even plastics. The stability of the insert-seat interface ensures excellent repeatability.
• Threading Tools - Threading inserts are available in both full and partial profile, covering pitch ranges from 0.25 mm up to 2.0 mm. Their unique design reduces vibration and ensures accurate thread profiles even at high spindle speeds.
• Turning Inserts (OD/ID) - With solid carbide construction and positive rake geometries, these tools are perfect for tight-radius turning, especially in miniature workpieces.
• Profiling & Chamfering Tools - Dümmel includes modular profiling solutions in the Minicut line, with toolholders that allow fast insert changes and reduced setup time. A variety of tip geometries are available for chamfering and contouring, ensuring maximum flexibility.

Toolholder Compatibility
The Dümmel system is backed by a well-designed toolholder family, including options for:

• Monoblock holders in round or square shank sizes
• Modular tool systems with clamping interfaces for high-pressure coolant through the holder
• Shank options in metric and inch dimensions to accommodate global CNC setups

This wide compatibility makes it easy to integrate Minicut tools into existing Swiss-style machines and gang-tool lathes.

Engineered Coatings and Materials
Minicut inserts come coated with Dümmel’s advanced TiAIN and DLC coatings, offering wear resistance and better chip evacuation. Specialized coatings are also available for non-ferrous materials, helping to extend tool life and reduce built-up edge formation.

Where the Minicut Line Excels

• Medical components – such as bone screws, dental parts, and implants
• Aerospace fasteners and bushings
• Electronic connectors and miniature housings
• Precision instrumentation and sensor housings

For high-precision turning tasks in difficult-to-machine materials or where micro-features are critical, Minicut delivers performance that production teams can trust.

Available Through Everede Tool – Supported by FTS
Factory Tooling Solutions is proud to support Dümmel’s Minicut tools as part of our partnership with Everede Tool, the exclusive importer of Dümmel products in North America. Whether you’re building your micro-machining program or seeking better tool life and part finish on Swiss lathes, the Minicut series offers the flexibility and precision your shop demands.

Ready to get started with Dümmel Minicut?

Reach out to your FTS representative for application support, tool selection guidance, and availability.

by Bernard Martin

If you’re looking to get into tight spots with precision, power, and no drama, Everede’s lineup of ANSI boring bars might just be your new best friend in the shop. Whether you're working on small holes, deep bores, or heavy-duty roughing, these tools are built to help you dig deep—and do it right.

Let’s break it down and see what makes Everede’'s ANSI boring bar selection such a solid choice for machinists who want both versatility and reliability.

Boring Bars Built to Go the Distance
Everede isn’t messing around. Their ANSI-standard boring bars cover a massive range, from micro to major. Each series is tailored for a specific type of work, but here’s the quick and dirty:

• Series A – Ideal for micro-machining and tight bores, getting into holes as small as 0.180".
• Series B – A solid step up for light roughing and finishing in bores from 0.270" and up.
• Series C to D – Perfect for general-purpose boring in medium to large diameter applications, up to 1.344".
• Series E through H – These bars give you great flexibility with boring diameters up to 1.094".
• Series FL – Spiral flute? Yes, please. Excellent chip evacuation for clean, consistent cuts in deeper bores.
• Series PB, TH & RCH – Niche bars for specialty cuts and setups—because sometimes your part just has that one weird feature.

Let’s Talk Inserts – Shapes That Get the Job Done
What really brings a boring bar to life? The insert, of course. Everede’s ANSI bars are designed to work with a few go-to insert shapes, and each has its own sweet spot:

• C-Style (80° Diamond, CCGT/CCMT): This is the all-rounder. Great for finishing or medium roughing. The large corner radius makes it stable and forgiving—perfect for general-purpose boring.
• D-Style (55° Diamond, DCGT/DCMT): Think tight corners and fine finishes. D-style inserts are great when you need a sharper angle to avoid walls or features. Expect great chip control and excellent surface finish.
• T-Style (Triangle, TCGT/TCMT): These are tough and aggressive. T-style inserts offer three cutting edges per side and are excellent for more robust applications where material removal is key. Great for cast iron or harder materials.
• W-Style (Trigon, WCGT/WCMT): Your go-to for maximum insert strength. With a wide cutting edge and beefy geometry, W-style inserts handle interrupted cuts or tough materials like a champ.

Everede matches the bar geometry and pocket depth to the insert style, so everything locks in smooth and performs like a dream.

Getting the Right Reach – Length-to-Diameter Ratios
We all know that going too far without the right support can end in chatter and tool failure. Everede’s got you covered with options that balance reach and rigidity:

• Steel Shank Bars: Safe up to about 4:1 L:D ratio. Ideal for shorter reach or shallow depth applications.
• Heavy Metal Shanks: These offer a solid middle ground—typically good for up to 6:1 L:D. The added mass and vibration-damping properties make them great for deeper cuts where chatter can creep in.
• Carbide Shank Bars: These give you extra backbone—up to 8:1 L:D is possible. Best when you're pushing into deeper bores and need maximum rigidity.

Cool Under Pressure – Standard vs. Coolant-Thru
Running dry or flood coolant? No problem. But when the chips are flying and the heat’s rising, Everede’s coolant-thru options are worth their weight in productivity. Keeping the insert cool helps extend tool life, improves chip evacuation, and keeps your tolerances tight.

Why Everede?
Built in the USA and backed by decades of application knowledge, Everede ANSI boring bars are built to last, easy to index, and just plain reliable. Whether you're running a manual lathe, CNC turning center, or tackling aerospace components, there's a boring bar in the lineup that’ll fit your job.

Want to learn more?
Check out the full catalog here:

And when you're ready to spec the right tool for your next job, give a shout out to the team at Factory Tooling Solutions. They’re happy to help you match the bar to the bore, the insert to the material, and the performance to the part.

by Bernard Martin

As new materials and technology push the limits of metalcutting performance, threadmaking faces new challenges. From hardened tool steels to exotic super alloys, the demand for tooling capable of threading these materials with precision, speed, and longevity has never been higher. Enter Carmex HBA — a carbide threading grade purpose-built to meet the demands of tomorrow’s toughest materials, available today.

Engineered for the Extreme
Carmex Precision Tools Ltd. developed the HBA carbide grade specifically for hard-to-machine materials like hardened steel up to 62 HRc, cast iron, Titanium, and high-temperature super alloys such as Hastelloy, Inconel, and Nickel-based alloys. At the core of HBA’s performance is its extra-fine submicron carbide substrate, offering high toughness and fracture resistance — crucial properties when threading brittle or abrasive materials.

What sets HBA apart is its optimized combination of substrate, coating, and edge geometry. This triad ensures excellent wear resistance, edge stability, and heat resistance — even under aggressive machining parameters.

Versatility Without Compromise
The HBA grade is available for both internal and external threading, supporting 60° and 55° partial profiles, as well as ISO metric and UN thread standards. This broad compatibility makes it a go-to solution for a range of demanding industries, from aerospace to die and mold, where workpieces often feature heat-treated surfaces or hard coatings.

Proven Performance in Hardened Steel
A recent real-world test highlights the capabilities of the HBA grade. In a threading application on D2 tool steel hardened to 53–56 HRc, a 16 ER 1.5 ISO insert was tasked with cutting an external right-hand thread, M32x1.5, over a length of 65 mm.

Running at a cutting speed of 147.6 SFM (45 m/min) — right in the middle of the recommended 100 to 195 SFM range for hardened materials with the HBA grade — the insert completed the thread profile in just 28 passes. It produced 36 threads per edge, showing not only solid productivity but also the kind of consistency and tool life manufacturers expect when working with high-value, hardened components.

A Solution for Hard Machining
As manufacturers continue to push into hard machining to reduce secondary operations and minimize setup time, the need for robust threading solutions grows. Carmex HBA allows users the ability to hold tight tolerances and maintain good surface finishes even in materials that traditionally pose significant challenges to tool life and performance.

Whether you're threading hardened tool steels in automotive applications or cutting threads in heat-resistant alloys for aerospace components, Carmex HBA offers a solution that blends strength, precision, and reliability.

Challenge Accepted
Carmex invites manufacturers, job shops, and engineers to bring their most difficult threading applications forward. With HBA, complex threading in hard and heat-resistant materials doesn’t have to mean sacrificing speed or tool life. Instead, it’s an opportunity to embrace the next generation of carbide performance — tough, precise, and fast. 

Get in touch with Factory Tooling Solutions and one of our team members will answer your questions and run some inserts if we think was can improve performance!