CNC milling in tool steel: How the mold for millions of bottles is made
How is the mold for millions of plastic bottles made?
In this video, we show the production of a negative mold made of extremely tough tool steel – milled with HAM standard tools.
The challenge: perfect surfaces, minimal tolerances, long running times.
Our solution:
– High-performance tools with HSF
– 5-axis machining
– Precise cooling
– Low-vibration machining
Titan Rim for JP Performance: The tools Behind the Project!
Our tools – built for titanium. Engineered for peak performance.
In collaboration with JP Performance, SolidCAM, and DMG Mori, a unique wheel was machined from titanium – a true milestone in precision and manufacturing technology.
In this video, we showcase our titanium tools in action – not yet on the wheel itself, but in other demanding real-world applications.
Even under MQL (Minimum Quantity Lubrication), our tools deliver uncompromising performance – efficient, precise, and reliable.
Turn-mill complete machining sounds like efficiency – but what’s really behind it?
In everyday production, there are often invisible hurdles that slow down processes:
🔴 Time-consuming set-up times and constant reclamping
🔴 Sources of error that jeopardize quality and delivery deadlines
🔴 Time-consuming measurements that slow down the process
At HAM, we experience precisely these challenges every day. In the “Drehvolution” workshop, we demonstrated live how a steel base body for a PCD tool is completely manufactured – from the first saw cut to deburring and measuring the final part. Turning, milling, measuring and deburring merge into a flowing process that does not require any manual reclamping.
A special highlight: the first live combination of the TC62 3D measuring probe from @BLUM with the Mazak machine. Real-time measurement values and automatic corrections during machining set a new benchmark for precision. The tool transfer from spindle 1 to spindle 2 ensures an uninterrupted process.
Aluminum machining live: How feed rate changes the surface – with in-process measurement
“Aluminum is easy.” – Really?
Maybe on paper. In practice, it often looks very different:
🔴 Tool wear that strikes faster than expected
🔴 Surfaces that do not become uniform
🔴 Greasy chips that stick to the tool
And all this despite the fact that the components are supposedly known. The cause rarely lies in the material alone, but almost always in the interaction of the entire process system.
In our workshop „Zerspanung ALU“, we took a close look at precisely this interaction: What makes aluminum so special as a material? What role does the synchronization of all process partners play? And what does a stable aluminum process look like that also works in practice?
The practical part was followed by direct implementation: two defined surfaces were produced using a PCD milling head with different feed rates – one with an Rz of 8 and one with an Rz of 13. We mastered demanding challenges such as thin-walled webs, ramps with different angles in the full groove with simultaneous axial and radial loads on the tool and low-burr holes.
Aluminum machining for e-mobility: LiCON LiFLEX I 17136 & HAM diamond milling cutter in action
What happens when two companies from Upper Swabia combine their strengths?
The result is more than just a project – it’s a vision realized through high-precision CNC machining, innovative manufacturing technology and a strong partnership.
We were able to contribute our expertise to a challenging project from LiCON: A battery frame made of the aluminum alloy AlSiMg for the e-mobility sector with dimensions of 1600 x 1300 x 115 mm was precisely machined on the high-performance LiFLEX I 17136 GigaLine machining center using our special diamond milling cutter system.
The result? The highest machining quality, maximum efficiency and absolute precision, supported by genuine trust and bundled expertise.
🤝 Thanks to the entire LiCON team for the strong collaboration and trust, true to the motto: “Global solutions from Upper Swabia into the world.”
Live steel machining in the workshop “The HAMamzing Smart Factory” | Digital Process Chain Live
🚦 Downtime or progress? Tomorrow’s production needs more than just precision. It needs intelligent processes that optimize themselves.
But the reality is often different:
🔴 Manual data input that provokes errors
🔴 Tool search times that waste valuable production time
🔴 Unnecessary downtime because processes are not optimally linked
Why are many companies still struggling with these problems, even though the solution already exists?
💡 The digital process chain is the key! Instead of using isolated individual solutions, we intelligently link all manufacturing processes – from initial planning to final machining. The result? Fewer errors, more efficiency, maximum productivity.
But what does this look like in practice? This is exactly what we demonstrated live at our showroom during our last workshop on the digital process chain. From tool planning and simulation to finished machining, participants were able to experience what modern production looks like today. Not just theory, but real solutions in action!
Live titanium machining in the workshop ‘Hart – Härter – HAMmer”
With their impressive hardness and dimensional stability, hardened materials stand for precision and durability. But machining them is a real challenge. In our last we combined both theory and practice and demonstrated live how hard machining can be achieved effortlessly.
*** The initial situation ***
🚩 Machining of a connecting rod mold through-hardened to 62 HRC (X155CrVMo12-1)
*** The challenge of hard machining (among other) ***
❌ Tool wear: Hard materials put a lot of strain on tools
❌ Heat generation: Insufficient cooling leads to high temperatures
❌ Machining parameters: Incorrect parameters affect precision and tool life
*** Our HAMazing solutions ***
✅ Selective carbide selection for optimum material properties
✅ Perfect adaptation of the tool geometry to the specific requirements
✅ Hyper smooth polished tool surfaces and reproducible main and secondary cutting edge preparation thanks to our unique Hybrid Surface Finish polishing process
✅ Optimal coatings for wear resistance, temperature resistance and friction reduction
Live titanium machining in the workshop ‘The Swabian Titan
With its outstanding strength and durability, titanium has become an indispensable part of modern manufacturing, even if its machining remains challenging. During our workshop last week, we demonstrated live how our new HAM titanium range and advanced cooling methods efficiently overcome this challenge. This is what future-oriented production looks like:
*** The initial situation ***
🚩 Machining of an aerospace part (150 x 110 x 50 mm) in grade 5 titanium (Ti6Al4V; 3.7164) completely with minimum quantity lubrication (MQL) only
*** The challenge of machining titanium ***
❌ Increased wear due to high cutting forces and temperatures
❌ Tool wear due to diffusion
❌ Due to the low thermal conductivity, the temperature is conducted into the tool
*** Our HAMazing solution ***
✅ 40-3011: Our 5-cutter for trochoidal milling
✅ 40-3001: Our 3-cutter for full-slot milling up to 1.5xD
✅ HAM Titandrill: Our process-reliable 3xD deep hole drill with internal cooling
Vollmer Werke GmbH and NUM AG new in the digital process chain of HAM Präzision
+++ HAMmer partnerships +++
We are expanding our digital process chain in the field of grinding with innovative partnerships.
These partnerships create new dimensions in the digital process chain:
- Modelling of special tools
- Production of special tools in minutes
- Implementation of customised special tools directly in the digital process chain
- Regrinding of tools directly in the digital process chain
A warm welcome to our new partners VOLLMER WERKE Maschinenfabrik GmbH and NUM AG. The Vollmer grinding machine Vgrind ARGON and the Numrotoplus software enable the production of special tools in minutes.
