• MAPAL offers complete machining solutions for the die and mould industry.

Iniciación en la fabricación de moldes y troqueles

Los fabricantes de moldes y troqueles esperan una elevada competencia en procesos y productos de su fabricante de herramientas de mecanizado. Pues la vida útil de los moldes que se deben crear y la precisión de las piezas moldeadas son fundamentales para la competitividad en la producción en masa. Por esta razón se exige la máxima precisión, una larga vida útil y, sobre todo, la seguridad del proceso a las herramientas.
​​​​​​​

Precisamente son estos aspectos los que hacen que MAPAL tenga éxito en sectores como la industria del automóvil, la construcción de máquinas o la industria aeronáutica. Por eso, la única lógica existente es que el fabricante de herramientas de precisión también ofrezca en la fabricación de moldes y troqueles soluciones eficientes y rentables para el proceso de mecanizado completo. Herramientas versátiles y precisas y adaptadores especiales con contornos estrechos y una concentricidad precisa minimizan los trabajos de pulido y de repaso gracias a una calidad de superficie constante durante el proceso de fresado. Estas permiten considerables ahorros económicos en el proceso completo.

Tool range for mould making

The picture shows the MAPAL tool range for mould making

Solid carbide end mills

  • OptiMill-3D-BN

    Frese a profilo sferico
    • Lavorazione ad alta precisione di contorni 3D
    • Range ø: 0,10 - 20,00 mm

  • OptiMill-3D-CR

    Frese a profilo torico
    • Fresatura a raggio angolare ad alta precisione
    • Range ø: 0,10 - 20,00 mm

  • OptiMill Frese a spallamento retto

    Frese a spallamento retto
    • Ideali per sgrossatura, finitura, fresatura trocoidale e fresatura di tasche
    • Range ø: 2,00 - 12,00 mm

  • OptiMill-3D-CS

    Frese ad ampio raggio per lavorazioni a 5 assi

    • Finitura di complesse superfici a forma libera e complicate geometrie del pezzo da lavorare
    • Range ø: 2,00 - 12,00 mm

  • OptiMill-3D-HF

    Frese ad elevato avanzamento
    • Ideali per la lavorazione ad alto avanzamento con grande volume di asportazione di materiale ed elevata sicurezza dei processi
    • Range ø: 2,00 - 16,00 mm

  • OptiMill-3D-Alu

    Frese a profilo sferico e torico
    • Lavorazione ad alta precisione di contorni 3D
    • Range ø: 1,00 - 20,00 mm

  • OptiMill-Graphite-MT

    Frese a profilo sferico e a spallamento retto
    • Frese multidente per sgrossatura per elevate velocità di asportazione con elettrodi di grafite
    • Range ø: 3,00 - 16,00 mm

  • OptiMill-3D-Graphite

    Frese a profilo sferico e torico
    • Adatte per la lavorazione di elettrodi di grafite
    • Versioni diverse a seconda della situazione di lavorazione
    • Range ø: 0,20 - 12,00 mm

  • OptiMill-3D-Copper

    Frese a profilo sferico e torico
    • Geometria speciale per la lavorazione di elettrodi di rame e leghe non ferrose dure
    • Range ø: 0,10 - 20,00 mm

  • OptiMill-Diamond

    Frese a profilo sferico, torico e a spallamento retto
    • Taglienti in PCD per un’elevata durabilità
    • Range ø: 3,00 - 12,00 mm

Frese con taglienti sostituibili

  • NeoMill-ISO-360

    Milling cutter with round inserts
    • Perfect for roughing and pre-finishing
    • ø range: 10.00 - 160.00 mm

  • NeoMill-3D-Finish

    Finishing milling cutter
    • Perfect for finishing 90° surfaces, face surfaces and contours
    • ø range: 16.00 - 42.00 mm

  • NeoMill-3D-Ballnose/-Torus

    Ball nose and corner radius milling cutter
    • One tool body with indexable insert for ball nose and corner radius milling for finishing and pre-finising
    • ø range: 8.00 - 32.00 mm

  • NeoMill-2/4-HiFeed90

    High-feed/90° shoulder milling cutter
    • Universal tool system to ensure maximum productivity
    • ø range: 16.00 - 200.00 mm

Drilling | Countersinking

  • ECU-Drill-Steel

    Foret en carbure monobloc  

    • Foret à deux arêtes de coupe avec un très bon rapport qualité-prix
    • Vaste gamme d'applications
    • Géométrie éprouvée pour un niveau élevé de précision et de fiabilité des processus
    • Plage de ø : 1,00 – 20,00 mm 

  • MEGA-Drill-Hardened

    Foret en carbure monobloc ultra-puissant 

    • Foret à deux arêtes de coupe avec revêtement et géométrie adaptés pour l'usinage fiable des matériaux durcis
    • Nouvelle micro et macro géométrie
    • Plage de ø : 2,55 – 16,00 mm 

  • MEGA-Drill-Steel-Plus

    Foret en carbure monobloc ultra-puissant 

    • Foret à deux arêtes de coupe avec revêtement et géométrie adaptés pour l'usinage de l'acier
    • Géométrie de la goujure optimisée et préparation d’arêtes de coupe modifiées
    • Plage de ø : 3,00 – 25,00 mm

  • Tritan-Drill-Steel

    Forets en carbure monobloc à trois arêtes de coupe 

    • Foret à trois arêtes de coupe pour une avance maximale
    • Arête transversale autocentrée pour les situations de perçage difficiles
    • Spécialement développé pour l'usinage de l'acier
    • Plage de ø : 4,00 – 20,00 mm 

  • Tritan-Spot-Drill-Steel

    Foret à pointer
    • Foret à pointer à trois arêtes de coupe pour les situations de centrage exigeantes
    • Spécialement adapté aux forets à trois arêtes de coupe
    • Plage de ø : 4,00 – 20,00 mm

  • Tritan-Step-Drill

    Foret étagé
    • Foret étagé à trois arêtes de coupe avec arête transversale autocentrée
    • Usinage de perçages taraudés sans mouvement pendulaire
    • Plage de ø : 4,25 – 14,15 mm 

  • MEGA-Deep-Drill

    Foret pour perçage profond
    • Fabrication fiable et efficace de perçages profonds jusqu'à 40xD
    • Foret pilote MEGA-Pilot-Drill
    • Plage de ø : 1,00 – 16,00 mm 

  • MEGA-Drill-Reamer

    Alésoir
    • Perçage et alésage – deux opérations réalisées par un seul outil
    • Arête d'alésage optimisée
    • Réduction des temps effectifs et non effectifs
    • Tolérance de perçage ≥ IT7
    • Plage de ø : 4,00 – 16,00 mm

  • Fraises à chanfreiner-noyer de précision

    Fraises à pas varié
    • Arêtes de coupe à espacement extrêmement variable
    • Niveau de précision plus élevé et valeurs de surface améliorées
    • Réduction des forces axiales et radiales
    • Réduction significative des vibrations
    • Paramètres de coupe améliorés pour une productivité maximale
    • Plage de ø : 4,30 – 31,00 mm 

  • MEGA-Drill-Reamer-Pyramid

    Alésoir avec pointe pyramidale 

    • Centrage, perçage et alésage en un seul outil
    • Propriétés de centrage améliorées grâce à la pointe pyramidale
    • Réduction des temps effectifs et non effectifs
    • Tolérance de perçage ≥ IT7
    • Plage de ø : 4,00 – 16,00 mm 

  • Forets à plaquettes de coupe QTD

    Foret avec système de tête amovible 

    • Système économique à plaquettes de coupe interchangeables
    • Système de serrage par liaison de force et de forme
    • Maniement simple
    • Précision élevée de concentricité
    • Plage de ø : 8,10 – 49,00 mm 

Alésage

  • FixReam – FXR

    Alésoir haute performance à queue cylindrique 

    • Alésoir haute performance en carbure monobloc
    • Goujure droite pour l'alésage débouchant et l'alésage borgne
    • Goujure oblique à gauche pour l'alésage débouchant
    • Plage de ø : 3,00 – 20,00 mm

  • CPReam – CPR

    Alésoir à tête amovible 

    • Stabilité et rigidité maximales grâce au cône et à l'appui plan
    • Précision de concentricité maximale de 5 µm
    • Maniement simple
    • Plage de ø : 8,00 – 40,00 mm

  • Alésoirs à réglage rapide – WN 50

    Alésoir manuel 

    • Alésoir à réglage rapide avec grande plage de réglage
    • Particulièrement adapté aux travaux de réparation
    • Jeux de lames de rechange disponibles
    • Plage de ø : 6,40 – 95,00 mm 

  • Outils guidés

    Outils avec patins de guidage 

    • Précision maximale grâce au concept MAPAL
    • Patins de guidage permettant un guidage direct dans le trou d'alésage
    • Plaquettes réversibles rectifiées
    • Réglage de haute précision pour un usinage au µm près 

Fixation d’outils
  • MAPAL UNIQ Chuck

    UNIQ DReaM Chuck, 4.5°

    Hydraulic chucks with a new design 

    • For reaming and drilling applications as well as for finishing during milling operations
    • This is achieved through an optimal interplay of geometric and functional properties
    • Outstanding surfaces as well as improved handling
    • Increasing productivity during the machining of contour-critical parts

    To the shop

  • MAPAL UNIQ-MillChuck

    UNIQ Mill Chuck, HA

    Hydraulic chucks with a new design 

    • Hydraulic chuck for highly dynamic milling applications
    • This is achieved through an optimal interplay of geometric and functional properties
    • Excellent results when using tools with HA shanks
    • Process reliability – even on high-quality parts 

    To the shop

  • HighTorque Chuck HTC

    Hydraulic chuck 

    • High level of torque transmission
    • Ideal damping properties
    • Excellent rigidity of the entire system
    • Radial run-out accuracy < 3 μm
    • 3° slim design for use in contour-critical applications 


       

    To the shop

  • MAPAL HydroChuck MHC

    HydroChuck MHC

    Hydraulic chuck 

    • Excellent vibration dampening
    • High degree of radial run-out accuracy
    • Ultra-short and compact design for high rigidity





       

    To the shop

  • ThermoChuck MTC

    Shrink chuck 

    • Long tool life through the use of high-temperature tool steel 
    • High torque transmission and radial rigidity
    • Precision balanced as standard
    • MQL-suitable
    • With and without axial tool length adjustment 

       

    To the shop

  • MAPAL MillChuck

    Mill Chuck, System HB

    Side lock chuck
    • Easy to handle thanks to use of a differential screw
    • Maximum cost-effectiveness and precision
    • Axial tool positioning can be defined using spring system
    • Decentralised coolant outlets for maximum process reliability



       
    To the shop

  • MAPAL Precision-DrillChuck MPC

    Precision-DrillChuck – MPC

    Precision drill chuck 

    • Simple construction, straightforward to handle
    • Safe clamping independent of direction of rotation
    • High degree of spindle speed strength
    • Modular design allows drill chuck heads to be used with all tool connections 

  • MAPAL slip-on reamer arbor

    Milling cutter arbor – MDA / MCA

    Milling cutter arbor 

    • Vibration-cancelling design (MDA) with vibration dampening system
    • Adapted to the rigidity of all common machine types
    • Smooth, stable running despite long projections delivers better surface finish
    • Milling cutter arbor (MCA) with large face connection for roughing and pre-finishing operations in large diameter ranges

  • MAPAL MFS milling head holder

    MFS milling head holder

    Tool adapter for screw-in milling cutter 

    • Simple and fast clamping of screw-in milling cutters
    • Exact interaction of taper and face connection
    • Greatest possible stability and rigidity
    • Universally deployable for roughing and finishing operations

  • MAPAL HSK adapter

    Adapter

    Extensions, reducers and adapters 

    • Wide range of options for modular tool systems
    • Hydraulic extensions and tool extensions for thermal expanding chucks
    • HSK reducers and extensions
    • KS steep taper adapter



       

    To the shop

Components and workpiece material

From the unmachined to the finished part

Find the right tool with just a few clicks: Depending on the machining, the specific operation and the tool requirement, you can quickly find the tool you want.
  • On a rendered example component, an operation is highlighted.
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    2D surfaces

    On the one hand, this category includes machining processes carried out directly on the machine, such as face milling, milling of pockets and straight walls. On the other hand, it also includes operations for complex geometries that are programmed using CAM software.

    Go to the product range for machining 2D surfaces
  • On a rendered example component, an operation is highlighted.
    2 / 8

    3D surfaces

    In the die & mould sector, the manufacture of increasingly complex forms is part of everyday life. Continuous further developments in machine tools and CAM software raise performance and productivity to an ever higher level. The tools used must therefore always be state-of-the-art. To achieve optimum results, each design starts with a process analysis.

    Go to the product range for machining 3D surfaces
  • On a rendered example component, an operation is highlighted.
    3 / 8

    Open pockets

    Mould inserts also have machining tasks that are required for casting or various attachment parts. Users are increasingly machining open pockets (circumferential machining) using trochoidal milling. This machining method helps to optimise machining times and to extend tool life.

    Go to the product range for machining open pockets
  • On a rendered example component, an operation is highlighted.
    4 / 8

    Closed pockets

    Closed pockets are usually produced by roughing in Z planes. When milling, a ramp is often selected as the machining entry. The tool selected depends on the depth of the walls and the mould incline to be generated on the component. MAPAL’s broad portfolio with modular systems also covers the machining of deep pockets with large diameters.

    Go to the product range for machining closed pockets
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    Helix milling

    A major focus in milling operations is on reducing the machining time. With specific tool geometries for machining closed, round pockets, it is often possible to eliminate the pre-drilling process. With helix milling, milling paths are programmed with helical entrances that are suitable for pocket dimensions.

    Go to the helix milling product range
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    Even surfaces

    Operations to create even surfaces occur very frequently and in different areas in the die & mould sector: It could be component-related, strategy-related due to the respective milling process or due to requirements for mould closing surfaces as well as sections and cutting dies. The right tool is then selected depending on the application and requirements.

    Go to the product range for machining even surfaces
  • On a rendered example component, an operation is highlighted.
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    Thin walls and ribs

    Plastic injection moulds and die casting moulds often have ribs and thin walls. Ribs, for example, are increasingly being milled, as this process is more cost-effective than EDM (spark eroding). As a rule, long or extra-long carbide tools with small diameters are used. Customer-specific solutions (RibCutter) to match the respective rib shape are also possible here.

    Go to the product range for machining thin walls and ribs
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    Small and large bores

    There is a wide range of full bore operations in the die & mould sector: From large bores for guide pillars and deep bores for the cooling system to high-precision bores for ejector pins. MAPAL offers a comprehensive portfolio of drilling and reaming tools for the individual production steps.

    Go to the product range for machining small and large bores

All from a single source

  • 1. Planning and purchasing

    Optimised purchasing management is important for a clear organisation of the tool stock.

  • 2. Tool logistics

    Cost-effectiveness even in the periphery of machining: Intelligent dispensing systems significantly reduce non-productive times.

  • 3. Engineering

    The machining specialists provide support with process engineering, e.g. in the form of CAM simulations, general advice and the development of economic machining strategies.

  • 4. Measuring and setting

    Reliable setting and measuring devices are convincing due to their accuracy and user-friendly operation when setting the tools.

  • 5. Tools and clamping technology

    From the spindle to the cutting edge – MAPAL offers a wide range of tools and clamping technology for the die & mould sector.

  • 6. Machining

    Efficient machining processes and customised machining strategies at the highest technological level.

  • 7. Digitisation and automation

    Quick and easy digitisation: The c-Connect Box digitally transmits measurement data from the setting fixture to the machine tool. It also monitors the machine status among other things.

  • 8. Reconditioning

    Customers receive their reconditioned tools back in manufacturer quality within a very short time. Also available with pick-up and delivery service upon request.

Engineering Workflow - From theory to practice

Finding the perfect solution for the customer is MAPAL’s main goal. In addition to individual custom solutions and a broad standard product portfolio, comprehensive services are available to optimally design the entire process from the product idea to the chip. Customers can rely on the technology leader’s many years of experience in machining.
  • 3D model of a workpiece from the die and mould making.

    1. Customer enquiry

    MAPAL sales representatives are directly available for individual enquiries. In a personal conversation with the customer, they sound out the specific requirements and the scope (complete or partial machining) and discuss the details directly on the 3D model of the component.

    The MAPAL die & mould team looks forward to your enquiry by ​​​​​​​Email and will contact you directly as soon as possible.

  • 3D model of a workpiece from the die and mould making.

    2. Project analysis

    On the basis of 3D models and machine data, the conversation partners analyse the manufacturing tasks and develop effective machining strategies.

    The project analysis consists of the following:​​​​​​​
    • Machining suggestions for all machining steps
    • Tool list
    • Process optimisation

  • 3. Process design

    Regardless of whether the focus is on flexibility or productivity: The machining specialists simulate the developed process on the basis of the 3D models and thus show potential for optimisation. They check and improve the machining parameters in CAM programming and thus ensure stable and economical production.

    The process design includes:​​​​​​​
    • Runtime analysis of the component
    • Technology data definition
    • CAM programming

  • Overview of all MAPAL tool solutions for die and mould making in one workpiece.

    4. Tool solution

    The wide-ranging MAPAL standard range for the die & mould sector offers the ideal tool solution for every application. Customised solutions are available upon request.

    Advantages for the user:​​​​​​​
    • Broad standard range
    • Availability of tool data

  • The picture shows a technical advisor from MAPAL in conversation with a customer.

    5. Tool test and offer

    After discussing the machining task, MAPAL supports its customers in the selection of tools required in the process. This is the basis for a well-founded offer tailored to the respective application.

  • The picture shows documents for preparing offers on a table with three people.

    6. パートナーシップによる協力

    共同で成功した後も、マパールの専門家はお客様と緊密に連絡を取り合います。時間の経過とともに最適化の可能性が出てきたり、他のツールの方が優れていると分かった場合は、マパールは生産性と費用対効果をさらに向上させるためのサポートを喜んで提供します。

    長期的に効率的な生産を実現するために、マパールは包括的なツールマネジメントのオプションも提供しています。

    ツールマネジメントのオプション:

    • ディスペンシングシステム
    • 再研磨サービス
    • 調整器や測定機器の豊富な製品ラインナップ

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