What is the best approach to mold machining when considering an all-in-one or combined solution?

Published 02/13/2026

Strategic Cutting Tool Pairing

Moldmakers can achieve faster, more precise results by combining indexable and solid round tools.

Rick Crabtree, Product Solution Manager, Sandvik Coromant

Evolving Industry

Moldmaking has long been a cornerstone of manufacturing. We only need to look at the bronze sculptures of ancient Greece, medieval weaponry and the parts produced during the Industrial Revolution to see it throughout history books. Today, moldmakers face a particular set of challenges.

Modern moldmaking is defined by the race to deliver complex, high-precision molds faster and more cost-effectively than ever before. With the increasing adoption of electric vehicles, consumer electronics and medical devices, the demand for highly complex molds made from hard, difficult-to-machine materials, such as hardened steel and high-performance alloys, is becoming increasingly commonplace.

One advantage of indexable tools is their ability to handle a range of operations, from roughing to precision finishing, all with the same toolholder by simply changing out the inserts and geometries. Some tools take these benefits further by achieving a better surface finish to reduce the need for a semi-finishing tool.

Mold Machining Demands

While injection molds often take center stage in discussions about moldmaking, forging dies and press tools represent another critical segment of high-performance tooling. This is especially true in industries such as automotive, aerospace, defense and heavy manufacturing where tools must endure extreme loads, repeated impact and thermal cycling while maintaining micron-level accuracy.

These parts are challenging to make. Forging dies experience extreme stress and thermal cycling and, therefore, are made from specialized heat-treated steels that can handle these demands. But heat-treated metals are very hard; often harder than most cutting tools can handle.

What’s more, forged parts often have complex shapes that require equally complex forging dies. These dies aren’t always made from a single solid block, but often in multiple pieces that fit together. Designing and building these multi-part dies is more difficult because each piece must align perfectly with the others.

Another challenge is the surface finish inside the die cavity. If the surface is too rough, the material poured into the die may not flow correctly, leading to defects in the finished part. Because of this, the final surfaces of the die cavities must be extremely smooth and precise, with no room for error.

Press tools used for stamping, blanking, bending and forming sheet metal share similar challenges.

Although their operating temperatures are not as extreme as those of forging dies, press tools experience high cyclical loads, abrasive wear and the need for high repeatability over potentially millions of strokes. Like forging dies, they are also manufactured from hardened tool steels and premature tool failure is a common concern.

Achieving a precise level of detail and surface quality in these applications is challenging, especially when working with hardened steel. These moldmaking applications require precise machining, often utilizing five-axis machines with supplementary polishing processes. These are all added steps that increase the complexity and time needed to finish the die properly, but they’re necessary to ensure the finished product is defect-free. It’s a double challenge for moldmakers: produce quickly, but while taking meticulous care to ensure a quality finish.

Indexable tools offer moldmakers a lifeline, capable of high feed rates and efficient chip control for more productive machining.

Indexable Tools Offer Versatility

When considering a tooling strategy, the proper pairing of indexable cutting tools and solid round tools can equal big benefits for mold builders. Indexable tools offer moldmakers a lifeline, capable of high feed rates and efficient chip control for more productive machining. With replaceable inserts that can be quickly swapped out when worn, indexable cutters can help reduce setup time and keep production running with fewer interruptions.

Another advantage of indexable tools is their ability to handle a range of operations, from roughing to precision finishing, all with the same toolholder. This versatility is achieved by simply changing the inserts and geometries, depending on the application, from light cutting to pocketing and ramping. This offers moldmakers greater versatility without a cumbersome setup. From a cost perspective, indexable tools are also a great consideration in moldmaking, as they support more efficient manufacturing by replacing only worn cutting edges rather than the entire tool. This makes them particularly attractive when machining expensive or difficult-to-machine materials, where tool wear can be high.

Recent developments in indexable cutting tools, such as one developed for high-feed pocket milling, further enhance these benefits by achieving a better surface finish, reducing the need for a semi-finishing tool.

Designed primarily for high-feed pocketing in ISO S, M, and P materials, this cutter features a robust shank design that combines a light-cutting action with stability to deliver vibration-free performance, even at long overhangs. Its curved, reinforced insert edge offers high security in corner machining, while an open insert pocket in the tool body and internal coolant ensure reliable chip evacuation, which is critical when working in deep cavities or hardened steels. An added bonus is that the light cutting forces use less machine power, resulting in reduced noise and less energy consumption.

A solid end mill can step in to refine contours, machine tight radii or achieve the final surface finish straight from the machine. This complementary role makes them indispensable in any moldmaking workflow where speed and precision must coexist. Superior edge retention ensures consistent performance over longer runs and helps maintain repeatability across multiple cavities and complex features.

No Need for Polishing

While indexable tools provide an effective solution for moldmakers, combining them with solid round tools can further enhance your machining strategy. Let’s look at solid end mills, which can serve as the finishing counterpart to indexable roughing tools. After a high-feed indexable cutter removes the bulk of the material, a solid end mill can step in to refine contours, machine tight radii or achieve the final surface finish. This complementary role makes them indispensable in any mold machining workflow where speed and precision must coexist.

Solid end mills produce exceptional surface finishes straight from the machine, providing moldmakers with a time-saving advantage under tight deadlines. If using specialized end mills that are capable of advanced finishing, manual polishing isn’t a necessary extra step in the production process.

What’s more, the sharp cutting edges and optimized geometries of solid end mills allow for more precise toolpath control in small or narrow areas such as tight internal corners or deep slots, where even slight tool deflection can compromise dimensional accuracy.

Another benefit of solid carbide end mills is their superior wear resistance and edge retention, even when machining hardened steels. This capability ensures consistent performance over longer runs and helps maintain repeatability across multiple cavities and complex features. When edge wear becomes an issue, some cutting tool manufacturers offer tool reconditioning services that restore worn solid carbide end mills to their original quality and prolong their total lifecycle.

Choosing between a combined tooling approach and an all-in-one solution depends on the balance of precision, speed and complexity needed for each mold machining job.

Taking the Best Approach

Choosing between a combined tooling approach and an all-in-one solution depends on the balance of precision, speed and complexity needed for each mold machining job. For molds with intricate features, challenging materials or deep cavities, combining an indexable cutter for fast, stable roughing with a solid carbide end mill for fine finishing ensures both accuracy and productive machining.

However, when part specifications are less demanding, an all-in-one solution may be a good option for faster machining with fewer cutting tool changes. The key is to understand the mold’s requirements and select a tooling strategy that can deliver the efficiency moldmakers seek without compromising performance.