• Finished tools are in production at Walter Formenbau. In the foreground a mould.
  • The picture shows different versions of the new circular radius milling cutter from MAPAL for die and mould making.

  • Technologically leading machining solutions

    More and more complex shapes are used in a wide variety of areas. This also increases the strategic importance of mould making for the most important industrial markets.

    Companies in the die & mould sector rely on the most advanced technologies with the aim of achieving maximum accuracy and cost-effectiveness in the shortest possible time.

    As a technology partner, MAPAL provides die and mould production with a high level of process know-how, technologically leading tools and services that exactly meet the needs and requirements of customers.

  • Walter Formenbau trusts in MAPAL’s expertise

    In order to achieve its goal of fully networked production, owner Dr Jens Buchert brought MAPAL on board as a full-range supplier.

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  • Efficient pre-finishing and finishing on 5-axis machines

    The solid carbide milling cutter for finishing of complex free-form surfaces and complicated workpiece geometries.

    Details
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    Ihr Technologiepartner für den Werkzeug- und Formenbau.

Getting started in the die & mould sector

Companies that make dies and moulds expect high process and product expertise from their cutting tools manufacturer. They require their tools to offer the highest levels of precision, a long tool life, and – above all – process reliability. It is precisely these aspects that make MAPAL successful in sectors such as the automotive industry, machine engineering and the aerospace industry. So it shouldn’t come as a surprise that the precision tool manufacturer is now also taking off in the die & mould sector.

Why use MAPAL?

  • All from a single source

    At MAPAL, customers can get everything they need from a single source and take advantage of our specialist knowledge of tooling and processing.

  • Partnership

    The basis of everything we do at MAPAL is a close, open dialogue with customers and, as a result, a long-term partnership on an equal footing.

  • Quality and precision

    MAPAL tools stand for the highest level of quality and cost-effectiveness. Characterised by excellent dimensional accuracy and the highest level of precision.

  • Standard programme

    The range of highly capable tools ensures excellent and reliable results for all machining tasks in the die & mould sector.

  • Technology leadership

    In the machining of cubic components, MAPAL is the technology leader worldwide.

  • On the ground all over the world

    Customer focus isn’t just a buzzword at MAPAL – it forms an essential part of our corporate identity. On a global basis.

All from a single source

  • Tools

    MAPAL offers the complete tool programme for the die & mould sector: from milling and drilling to countersinking and reaming.

  • Clamping technology

    Performance and process reliability – as well as radial run-out and changeover accuracy – in every application are guaranteed by the clamping technology range from MAPAL.

  • 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.

  • Technology centre

    Rehearsing for the real thing: In the technology centre in Aalen, customers have many options for trying out machining operations or doing tests.

  • Reconditioning

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

  • Tool logistics

    Economic efficiency even in the periphery of machining: With intelligent output systems and setting fixtures, MAPAL significantly reduces non-productive times.

  • Digitisation

    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.

  • Training

    Comprehensive on-site training at the customer or in the MAPAL Academy at the headquarters in Aalen.

Technology & Solutions

Product programme & highlights

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    OptiMill-3D-BN ball cutter

    High precision machining of 3D contours:

    • High precision milling cutters with a high level of radius accuracy
    • With and without working depth
    • Available in cylindrical and conical forms
    • For a wide range of materials
    • Wide selection for hard and soft machining of steel
    • Different numbers of teeth available
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    OptiMill-3D-CR corner radius milling cutter

    Milling with a very precise corner radius

    • ​​​​​​​Finishing of 3D moulds
    • High precision corner radius with high level of radius accuracy
    • For a wide range of materials
    • Wide selection for hard and soft machining of steel
    • Different numbers of teeth available
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    OptiMill-3D-CS shoulder radius milling cutter

    Milling with a large operating radius

    • ​​​​Finishing of complex free-form surfaces and complicated workpiece geometries
    • Higher axial material removal rate with a much better surface finish compared to a full radius milling cutter
    • Short machining time due to large line interlacing​​​​​​​
    • Teardrop form and taper shape
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    OptiMill-3D-HF high-feed milling cutter

    Milling at high feed rates

    • Perfect for high-feed machining with a high material removal rate and high process reliability
    • For the hard and soft machining of steel in particular
    • Different numbers of teeth available
    • Extremely quiet running​​​​​​​
    • High process reliability thanks to innovative face geometry
    ​​​​​​​
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    OptiMill shoulder milling cutter

    Different variants made of solid carbide and with indexable inserts for roughing, finishing, groove milling, ramps and pocket milling

    • ​​​​​​​For 2D/2.5D machining
    • Extremely long tool life
    • Excellent dimensional accuracy
    • Designs available with different lengths
    • For a wide range of applications and materials
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    OptiMill-Trochoid trochoidal milling cutter

    Trochoidal milling

    • Maximum material removal rate while providing an excellent surface finish
    • Pre-machining and fine machining with one tool
    • Cutting depth up to 5xD
    • Extra long cutting tool
    • Optimised unequal spacing and finely balanced cutting tool for protecting the machine spindle and a longer tool life
    • ​​​​​​​Chip breaker for optimum chip control
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    OptiMill chamfer and deburring milling cutters, engravers

    • Economic chamfering and deburring of pre-machined parts
    • Engravers for engraving fonts and contours and for copy milling
    • Drill milling cutter for combination machining in one machining step, especially for sheet metal and thin-walled parts
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    NeoMill-3D-Ballnose and NeoMill-3D-Torus ball and toric end milling cutters

    Pre-finishing and finishing of 3D contours

    • ​​​​​​​Universal milling system to ensure maximum productivity
    • A tool body with ball and toric plates for pre-finishing and finishing
    • Special tool body for toric plates with the highest precision and process reliability requirements
    • Highly accurate rotational tolerances
    • Perfect surfaces thanks to low-vibration solid carbide tools
    • Increased process reliability guaranteed by using ultrafine grain carbides
    • Available as shank and screw-in milling cutters
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    NeoMill-ISO-360 round-insert milling cutters

    Roughing and pre-finishing of 3D contours

    • ​​​​​​​Cutting materials and chip guiding stages are available for soft machining as well as hard/finish machining
    • High-precision contours due to the indexable inserts being installed in a neutral position
    • Chip discharge protection
    • Available as shell type, shank and screw-in milling cutters​​
    • Soft cutting behaviour for low vibration machining
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    NeoMill-2-HiFeed90 and NeoMill-4-HiFeed90 high-feed and 90° shoulder milling cutters

    Milling at high feed rates

    • ​​​​​​​Universal tool system to ensure maximum productivity
    • Tool body with indexable inserts for high-feed and shoulder milling
    • Maximum rate of removal due to very high feed rates and large cutting depths
    • Tool and storage costs are reduced
    • Double-edged and four-edged indexable inserts available
    • Offered as shell type, shank and screw-in milling cutters
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    NeoMill-3D-Finish finishing milling cutter

    Finishing of 90° surfaces, face surfaces and contours

    • Axial and radial indexable wiper inserts available to provide an excellent surface finish
    • Vibration-free machining for long projections
    • ​​​​​​​Available as screw-in milling cutters
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    Drilling and countersinking

    • Double-edged and three-edged solid carbide drills for drilling from solid in steel, hardened steel, stainless steel and cast iron
    • Deep hole drill for making deep bores up to 40xD
    • Precision countersinks with unequal spacing for greater precision and better surfaces
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    Reaming

    Fixed multi-bladed reamers and tools with guide pads
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    Clamping

    • Hydraulic, thermal and mechanical chucks for reliable tool clamping and optimum machining results
    • Extensions, reducers and adapters enhance the possibilities

Highlights during milling

Highlights during drilling

Highlights during clamping

Company

The picture shows the main MAPAL plant in Aalen from the outside.

Technology leader for the machining of cubic parts

The manufacture of custom tools has been MAPAL’s core business for 70 years. For this reason, the focus has been on comprehensive advice and support for machining tasks and processes since the company was founded.

MAPAL tools stand for the highest level of quality and cost-effectiveness. This is guaranteed by uniform, state-of-the-art production facilities and standardised production processes worldwide.
 
More about MAPAL

MAPAL in figures

  • The picture shows a MAPAL groove milling cutter in use.

    1

    Technology leader for the machining of cubic parts

  • In the picture, the viewer takes a look into the MAPAL test and development center in Aalen.

    6

    Annual investment in research and development of 6% of turnover

  • On the world map, the countries with MAPAL subsidiaries are highlighted in green and the countries with sales representatives in light green.

    25

    Subsidiaries with production, sales and service in 25 countries

  • In the picture, two trainees check the accuracy of a tool.

    300

    More than 300 trainees worldwide

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

    450

    Over 450 technical consultants on the road

  • Two MAPAL employees at their desks can be seen in this picture.

    5,500

    Our most important asset: more than 5.500 employees worldwide

Contact

Two people in conversation

Your direct contact MAPAL Team Die and Mould die-and-mould@mapal.com +49 7361 585-0