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Components and workpiece material

Steel and hardened steel

Steel and hardened steel

Parts that become more and more complex with increasingly deep cavities as well as moulded and reinforcement ribs in plastic injection moulds and pressure die casting moulds necessitate the use of extra long tools with diameters that can be very small. Complex part geometries and various material characteristics place the highest demands on machining and tool life.

Application examples:

• Plastic injection mould
• Pressure die casting mould

To the machining of a plastic injection mould insert

Cast iron

Cast iron

For designing, engineering and constructing medium- and large-sized cold forming tools, cast iron is often used due to material properties such as compressive strength and easy machinability. The main components here are mould plates and mould inserts. Here, MAPAL has a lot of experience with milling (2D and 3D) and drilling operations (drilling, reaming, thread cutting).

Application examples:

• Mould plates
• Mould inserts

Aluminium

Aluminium

When it comes to pre-series or prototype moulds, it is not unusual to use materials that are easy to machine. Aluminium alloys or uriol (plastics) are often used. In these cases, solid carbide tools with positive and partly polished cutting edges, or better still, PCD-tipped tools ensure high productivity and short machining times.

Application examples:

• Pre-series moulds
• Prototype moulds

Copper

Copper

Manufacturing of electrodes for EDM processes requires machining of copper alloys and graphite materials. The selection of the electrode material depends on the requirements of the mould to be created. Copper alloys are comparatively expensive and are generally used for finishing the electrodes, when it comes to high surface quality and shape accuracy. Solid carbide end mills with special geometries by MAPAL guarantee high-precision machining results here.

Application example:

• Electrodes for spark eroding (EDM)

Graphite

Graphite

Graphite has a highly abrasive effect on the tool and causes strong wear on the cutting edge. The profiles to be machined tend to burst with increasing wear. Therefore, a tool with suitable geometry and optimum cutting material is required. For machining graphite, MAPAL uses diamond-coated solid carbide tools or PCD-tipped tools.

Application example:

• Electrodes for spark eroding (EDM)

From the unmachined to the finished part

All from a single source

Engineering Workflow - From theory to practice

• 13.04.2026

  IMPULSE 86 has been published

  In the current issue of the technology magazine IMPULSE, the main topics are the merger of the German sites and the aerospace sector.

  #Setting #Company #Industries #CaseStudies #Technology #Milling #Events #Aerospace #Die&Mould #Services

• 02.12.2025

  Large tool package for Mangner Zerspanungstechnik

  MAPAL has equipped Mangner GmbH with a comprehensive tool package for drilling operations.

  #Drilling #CaseStudies #Die&Mould

• 04.03.2025

  CORMOL relies on milling cutters such as the OptiMill-3D-HF from MAPAL for tool making

  CORMOL from Portugal manufactures stamping tools, for which it has been working closely with MAPAL since 2022. With the OptiMill-3D-HF, CORMOL has found a reliable and economical tool solution.

  #Products #Industries #CaseStudies #Technology #Die&Mould #Milling

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