A large defense contractor was machining a plastic defense frame component with a 0.125″ diameter 4-flute carbide ball-nose end mill. The tool could produce the required shape, but it took 291 passes
and 7,268 seconds per part.

At 1,000 parts per year, the process created a major bottleneck. The issue was not the cost of the tool. It was the time lost using a small ball-nose end mill for a form that needed a faster, application-specific
solution.

The customer asked GWS Tool Group to reduce cycle time, lower production cost, and keep a critical defense program on schedule.

GWS designed a custom 0.750″ diameter shaped 5-flute end mill built to match the required form. Instead of using a small ball-nose tool for 291 passes, the new tool completed the operation in two passes: one roughing pass and one finishing pass.

Cycle time dropped from 7,268 seconds per part to 39 seconds per part. At 1,000 parts per year, that reduction saves approximately 2,008 machine-hours annually, based on the submitted cycle-time data.

The customer reported $1,102,448.32 in annual machine time and labor savings, not including added production capacity. The improvement helped protect the current contract and secure an extended production contract.

The project shows the value of matching the tool to the operation. The custom tool cost more per piece, but it removed the true bottleneck: a 291-pass process that was too slow for production demand.

Need to take time out of a difficult milling operation?

If repeated passes, long cycle times, or an inefficient toolpath are slowing production, GWS can review the application and help determine whether a standard, modified-standard, or custom tool is the right fit. Contact your local GWS application specialist to discuss your project.