Among our many satisfied customers is a defense systems manufacturer based in the Midwest. Known for their precision work and commitment to quality, they faced a critical challenge in producing parts using forgings. Initially, they invested in a 30-taper CNC machine, which proved inadequate for the job. The lack of rigidity and spindle resonance negatively impacted tool life, preventing the manufacturer from achieving the desired results.

Determined to find a solution, they initially turned to well-known brands, purchasing end mills that cost over $250 each. Despite the high price tag, the tool life was disappointing, averaging only 55 parts per end mill.

Everything changed when they discovered GWS Tool Group’s Alumigator end mills and one of our broaching tools from our armory line of products.

By switching to GWS Alumigator tools—including 3/8″ and 1/4″ end mills, as well as 1/2″ ball nose end mills—the manufacturer saw tool life skyrocket to 1,500 parts per end mill, a remarkable improvement. “I’ve replaced pretty much everything with Alumigators for high-volume work,” said the customer. “These tools just excel, and I’ve never had one fail.”

The enhancements didn’t stop at tool longevity. The customer also experienced significant efficiency gains, with machine feed rates increasing from 60 inches per minute (IPM) to 130 IPM at 16,000 RPM. In terms of cycle time, they reported a reduction of approximately 20%. The broaching tool was also a game-changer, delivering flawless performance right from the start.

Looking for Tools That Deliver Superior Performance?

Whether you’re in the defense sector or other high-demand industries, GWS Tool Group has the expertise and solutions to help you optimize your production. If you have specific needs that go beyond our standard offerings, our dedicated engineers are ready to design and deliver custom tools tailored to your exact requirements—all with rapid turnaround times. Email us today at sales@gwstoolgroup.com.