“Precision machining technologies, including multi-axis CNC systems, are essential for producing the intricate geometries required. Moreover, digitalisation tools, such as CAD/CAM integration, simulation, and predictive maintenance, can help reduce errors and optimise tool life,” says Sunil Joshi, President – Sales, Sandvik Coromant, India, in conversation with Neha Basudkar Ghate.
How do advancements in digital technologies and Industry 4.0 impact the efficiency and precision of die and mould manufacturing processes?
Advancements in digital technologies and Industry 4.0 are significantly enhancing the efficiency and precision of die and mould manufacturing. Tools such as CAD/CAM software, simulation platforms, and digital twins allow manufacturers to design and test dies virtually, reducing trial-and-error and ensuring first-time accuracy.
On the shop floor, smart CNC machines integrated with IoT sensors and AI-driven controls enable real-time adjustments to cutting speeds and toolpaths. This results in higher precision, lower scrap rates, and the capability to run ‘lights-out’ operations. Predictive maintenance, powered by sensors and analytics, minimises unexpected downtime, while automated inspection systems ensure moulds meet tight tolerances without slowing production.
Industry 4.0 facilitates seamless data integration across the manufacturing value chain, enabling better scheduling, faster turnaround times, and closer collaboration with customers. Together, these technologies make die and mould manufacturing more agile, accurate, and competitive.
What are the most pressing challenges for the tool and die manufacturing sector today? How can these challenges be effectively addressed at the industry level?
One of the most pressing challenges facing the tool and die manufacturing sector today is the shortage of skilled labour. Toolmaking requires highly specialised knowledge. With many experienced workers retiring and fewer young professionals joining the workforce, the industry is currently facing a significant talent gap. This shortage can slow production and also put critical expertise at risk. Expanding apprenticeship programs in partnership with trade associations and manufacturers can effectively address this challenge at the industry level.
Global competition and rising costs pose another challenge. Domestic manufacturers often struggle to compete with lower-cost overseas firms, particularly in countries that offer cheaper labour and government subsidies. Increasing material and energy costs further squeeze margins for local tool and die makers. Collective reshoring initiatives, supported by policy incentives such as tax credits and grants, could make domestic production more competitive and serve as an industry-wide solution to address this issue. Additionally, investing in productivity-enhancing technologies, such as digital twins, lean practices, and automation, can reduce waste and increase efficiency across the sector.
Another key challenge is the slow pace of technology adoption. Customers in industries such as automotive and aerospace demand faster turnaround times and greater customisation. To remain competitive, toolmakers must modernise. Industry leaders can address this by establishing regional innovation centres where small and medium-sized firms can experiment with new technologies without having to bear the full investment risk. Sandvik Coromant has a global network of Centres, including the one in Pune, India, which provides valuable platforms for customers, partners, and future generations to explore new technologies and find solutions to their challenges.
How does Sandvik Coromant address the challenges posed by the use of advanced materials in industries like aerospace and automotive, particularly in relation to cutting tool development?
Industry requirements primarily drive material selection. So, when it comes to material standardisation, there is little we can influence. For instance, if the aerospace sector decides to use Inconel or Titanium for a specific component, those choices are dictated by performance needs. What we do see, however, is a clear trend toward using advanced materials to enhance component effectiveness and efficiency.
In the automotive industry, for example, turbochargers have historically evolved from being manufactured in SGI (Spheroidal Graphite Iron) to steel, stainless steel, and, more recently, SIMO. The real challenge, both for us and the industry, lies in developing cutting tools that can consistently machine such diverse materials. A cutting tool grade suitable for SGI would not perform effectively on SIMO. To address these requirements, we are continuously innovating by introducing new tool grades, geometries, and coating technologies specifically designed to machine these difficult-to-cut advanced materials.
How can the tool and die industry adapt to the growing demand for advanced materials and complex geometries, especially in sectors like automotive and aerospace?
To meet the growing demand for advanced materials and complex geometries, the tool and die industry must adopt new technologies and smarter manufacturing processes. Sectors like automotive and aerospace increasingly use lightweight alloys, composites, and high-strength steels. These are more challenging to machine and place greater demands on tooling. Manufacturers need to invest in advanced cutting tool materials, such as coated carbides, which can withstand high wear and elevated temperatures.
Precision machining technologies, including multi-axis CNC systems, are essential for producing the intricate geometries required. Moreover, digitalisation tools, such as CAD/CAM integration, simulation, and predictive maintenance, can help reduce errors and optimise tool life.
Collaboration with material suppliers and ongoing workforce training are equally crucial to enable toolmakers to develop customised solutions that can enhance efficiency, extend tool performance, and satisfy the evolving requirements of advanced applications in the automotive and aerospace sectors.
What is Sandvik Coromant’s Manufacturing Wellness vision? Why is it relevant today?
Sandvik Coromant’s Manufacturing Wellness vision promotes sustainable growth by encouraging manufacturers to implement eight positive habits that balance economic progress with environmental responsibility. This mindset focuses on efficiency, innovation and collaboration across the entire value chain. By making use of advanced technologies, data-driven insights and workforce development, manufacturers can optimise processes, reduce waste and minimise energy use.
This vision is particularly relevant today as India strives to reduce its 2021 carbon dioxide emissions by 22% by 2030 while meeting half of its energy requirements from renewable sources by the same year. Sandvik Coromant has developed new technologies to support manufacturers in this process, such as its Sustainability Analyser which allows manufacturers to measure — and consequently reduce — energy consumption and carbon emissions.
Can you explain how simulation and optimisation technologies contribute to improving efficiency and productivity in manufacturing processes?
Simulation technology enhances manufacturing efficiency by allowing users to digitally test and refine the programs or processes they plan to run on their machines. This helps in optimising cycle times and starting operations with greater precision. Optimisation software further supports production by reducing non-cutting and non-value-adding time on the machine, thereby boosting overall efficiency and productivity. Together, these technologies streamline operations and help manufacturers achieve maximum output.
How is the integration of simulation and optimisation software transforming the tool and dies production landscape?
The integration of simulation and optimisation software is significantly reducing reliance on trial-and-error and accelerating tool and die production. Simulation tools enable manufacturers to virtually test tool designs, which helps them predict potential issues, including warping, cracking, and premature wear, before physical production actually begins. This not only saves time and material costs but also improves design accuracy and reliability.
Optimisation software further enhances this process by refining designs for efficiency, durability, and performance, ensuring that the dies withstand the challenges of forming advanced materials such as high-strength steels and composites. These tools help manufacturers adapt to the increasingly complex geometries that sectors like automotive and aerospace demand.
To sum it up, by cutting lead times, lowering costs, and extending tool life, simulation and optimisation software enable tool and die makers to remain competitive while delivering the precision and efficiency required in today’s manufacturing environment.
This interview was published in TAGMA Times
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