by Bernard Martin

If you’ve ever hesitated to switch from solid reamers to a replaceable-head system due to accuracy concerns, the MAPAL HPR series was built to address your issue. It’s designed to give you the same level of bore quality you expect from a monolithic reamer, with the added benefit of faster changeovers and lower long-term tooling costs.

At the heart of the HPR system is MAPAL’s precision head-to-body interface, which is engineered to control radial runout extremely tightly. That means you can swap a head on the machine and still hold your bore size and position without chasing offsets or second-guessing the setup. Once it’s dialed in, it stays consistent from part to part and batch to batch.

The HPR platform covers nominal diameters from Ø8 mm up to Ø65 mm, with replaceable heads available in 0.10 mm diameter increments and stocked preferred sizes aligned to ISO H7 tolerance classes. In practice, that allows one tool body to support multiple adjacent bore sizes within a job family while still holding finished bore tolerances in the single-digit micron range.

MAPAL specifies radial runout at the cutting edges of ≤ 3 µm after head change, placing the HPR system squarely in solid-reamer territory from an accuracy standpoint.

For process flexibility, the HPR range includes both fixed-head versions for maximum rigidity and finely adjustable heads with a diameter adjustment range of ±0.02 mm, allowing size correction directly at the tool without regrinding or replacing the head prematurely. This adjustability is particularly useful when compensating for wear, thermal drift, or material variation, and it reduces offset chasing while extending usable head life. The result is predictable size control across long production runs without adding complexity to setup, tool presetting, or floor-level tool management.

Cutting material and coating options are where the system really starts to shine across different materials. Whether you’re running steels, cast iron, aluminum, stainless steel or exotic alloys, the available carbide, cermet, PcBN, and PCD heads allow you to match the tool to the job instead of forcing one reamer to do everything. The coatings are designed for heat control and wear resistance, which translates directly into predictable tool life rather than surprise failures.

Coolant delivery is handled internally and directed right to the cutting edges. That helps with chip evacuation, keeps heat under control, and supports both flood coolant and MQL strategies. In deeper bores or tougher materials, this becomes a real advantage, especially when you’re trying to maintain surface finish without backing off feeds and speeds.

The biggest advantage of the MAPAL HPR system is how it changes your cost structure. When a cutting edge is worn, you’re replacing the head instead of the entire tool. That reduces spend, simplifies inventory, and shortens recovery time when a tool reaches the end of its life. Over the course of a production run, that adds up quickly.

HPR defines the upper end of precision within MAPAL s replaceable-head reaming systems.. It’s built for shops that demand precision first, but still want the flexibility and economic advantages that come with modular tooling. In an upcoming article, the CPR series will make a good contrast by showing how MAPAL approaches cost-optimized reaming for high-volume work—but HPR is where precision sets the benchmark.

Factory Tooling Solutions is excited to announce our return to the Wichita Industrial Trade Show 2025 (WITS), taking place October 21–23, 2025 at the Century II Performing Arts & Convention Center in Wichita, Kansas. As one of the largest regional manufacturing and machining trade shows in the Midwest, WITS 2025 brings together professionals from across the industrial, aerospace, agricultural, and energy sectors to explore the latest in machine tools, precision tooling, automation, workholding, and metalworking technology.

Held every other year since 1974, the Wichita Tool Show has built a strong reputation as a must-attend event for manufacturers, engineers, and industry leaders throughout Kansas, Oklahoma, Missouri, and surrounding states. Factory Tooling Solutions will be showcasing product innovations from all 19 of our world-class principals, giving attendees a hands-on look at the cutting tools, toolholding systems, workholding, and metalworking fluids that drive manufacturing efficiency and precision.

Our booth will feature a wide-ranging display of tooling innovations and solutions from all of the world-class principals we represent. This is a great opportunity to get hands-on with the latest products featured on our website and speak directly with the FTS team about your application challenges.

Explore the Full Factory Tooling Solutions Lineup
You’ll find product samples and technical displays from across our lineup, including:
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• Boneham Metal Products (BMP) – Dowel pins, drill bushings, and custom precision components
• Carmex – Thread milling tools, DMT carbide, and laydown inserts
• Canela – Lathe holders, ISO boring bars, and turning tools
• Dümmel – Ultra Mini and Swiss Line micro-machining tools
• Everede – Specialty boring bars, indexable ANSI tools, and custom form tools
• Fullerton Tool – High-performance end mills like VMAC, Fury, and Aluma series
• Greenleaf – Advanced ceramic inserts and tooling for titanium and Inconel
• Hangsterfer’s Laboratories – High-performance coolants like 5080, Hardcut GTL, and S 500CF
• HEULE Tool – COFA, BSF, and other automated back chamfering and deburring tools
• Huot – ToolScoots, CNC tool storage systems, drill dispensers
• Jergens Workholding – Ball Lock, 5-Axis vises, tombstones, and quick-change fixturing
• MAPAL – Replaceable head reamers, QTD indexable drills, and PCD tooling
• Nine9 – Spot drills, chamfer mills, engraving and centering tools
• OMG – Right angle heads, speed increasers, and facing heads
• Rego-Fix – Powergrip, ER collets, and RE Cool coolant-through technology
• Riten Industries – Live centers, face drivers, and workholding support products
• Rocky Mountain Twist – Cobalt drills, threaded shank drills, and micro stop countersinks
• Superior Abrasives – Quick-change discs, flap wheels, and convolute finishing products
• Tanis Brush – Disc brushes, bore hone brushes, and abrasive filament tools

See What’s New – and What’s Next
If you’re looking to stay competitive in precision manufacturing, you won’t want to miss this event. Our team will be on-hand to guide you through tooling strategies, help identify cost-saving opportunities, and match your application with the right products.

Whether you’re optimizing for cycle time, surface finish, or material removal rates, FTS has the solutions to help you stay ahead.

We look forward to seeing you in Wichita this October!

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.