Advanced Tool & Die

Our Process

As a leading tool & die manufacturer, EagleMatic takes pride in offering a comprehensive range of exemplary tool and die shop services. Our expertise lies in the design and build of new tooling, setting us apart in the industry. Our experienced die designers bring innovative ideas to each custom-ordered part, ensuring the finest quality product. From part print to finished part, we have the capability to build your tools entirely in-house. Our commitment to excellence and customer satisfaction drives us to continuously improve our die-making processes, ensuring that we deliver the highest quality products to our clients.

Quality is at the forefront of our approach, encompassing every stage from prototype and validation to installation. Leveraging advanced technology and innovative systems, we design, test, and manufacture high-quality tooling. Our services include Die Simulation, 3D CAD Modeling, and Die Design, with all of the components CNC machined for unsurpassed accuracy. Our skilled tool and die makers, assemble and validate the tooling during the manufacturing process, supported by our cross-functional team utilizing the latest computerized scanning and inspection technologies for precision and durability. At EagleMatic, we are dedicated to upholding the highest standards of quality and precision in our manufacturing process.

Furthermore, our engineers employ cutting-edge technology and software to perform simulations for successful tooling designs and material selections. Our Die Simulation process guarantees that the production material, product geometry, and tool process can withstand the demands of the production environment. We address common problem areas during Die Simulation, ensuring optimal performance and reliability. By integrating the latest advancements in tool and die-making technology, we ensure that our customers receive products that are not only of the highest quality but also meet their specific requirements.

Benefits

At EagleMatic, our Die Design services are backed by years of retained intellectual property and training on the latest technology, in order to assist clients with their needs. Some of the benefits you will find are: advanced Die Simulation, precision CNC machining, and a team of skilled tool & die makers dedicated to delivering exceptional results. Our commitment to innovation and continuous improvement allows us to provide our clients with custom die solutions that are tailored to their unique requirements, ensuring that they receive the best possible outcomes for their projects.

Shortened lead times
Maximized material utilization
Eliminated waste
Maximized production speeds
Improved overall quality of the part

Our expertise in tool and die making allows us to redesign parts that have traditionally been produced using more costly manufacturing methods such as casting, hydroforming, or clamshell stamping processes. This not only helps our customers find new ways to improve performance, reduce weight, improve quality, and reduce cost but also demonstrates our commitment to delivering innovative and cost-effective solutions through our tool and die processes.

Manufacturing Capabilities and Services

CAD/CAM Design and Engineering utilizing: AutoCAD®, SolidWorks®, MasterCAM®, MetaCAM®, and Camtek®
High Speed CNC Machining for material up to 48″ wide x 96″ long
Precision Wire EDM with cutting capacity of materials up to 18″ thick
Meticulous precision Surface, Blanchard, and Jig grinding, holding tolerance as tight as +/-0.0002
Laser and Water Jet Cutting for any materials up to 72″ wide x 162″ long x 8″ thick
Complete Controls Engineering for everything from Pneumatics to Hydraulic, Servos, and Robotics
Punch Dies / Tooling and Machine Build including Tryout and Runoff
Weldments, Fabrication

4 & 5-axis machining

In our shop, we leverage the precision and efficiency of 4 and 5 axis mills to produce superior-quality tooling and dies. This advanced technology allows us to execute complex geometries with unparalleled accuracy, minimizing the need for manual adjustments and reducing production time. The 5-axis mill, in particular, offers the ability to process a workpiece from multiple angles in a single setup, enhancing the overall quality and precision of the finished product. By integrating these cutting-edge technologies into our production process, we are able to deliver products that meet and exceed our customers’ expectations, while also optimizing their production costs and lead times.

Custom Made

Our custom engineering approach ensures we meet our customers’ diverse needs effectively. We create simple dies that achieve functions with single strokes, offering speed and precision. Our compound dies perform numerous cutting actions at individual stages with one stroke, promoting efficiency. Multi-Stage dies, on the other hand, implement various cutting and punching operations and cut off at the final stage, enhancing production flow and increasing output. This flexibility and customization offer significant benefits to our customers, showcasing our commitment to meeting their unique tooling requirements.

Data Collection

We utilize advanced data collection methods in our die manufacturing process to enhance efficiency. By systematically gathering, analyzing and interpreting relevant data, we are able to optimize the production processes, reduce waste, and increase output. The collected data also offers valuable insights into performance metrics and predictive maintenance, enabling us to provide our customers with tangible data they can use for strategic decision-making and training. This data-driven approach not only improves their operations but also empowers our customers, facilitating a seamless and productive partnership built on trust and transparency.

Waterjet Tooling

We utilize our advanced waterjet in our tool and die manufacturing process, providing significant customer benefits. Our waterjet precisely cuts a variety of materials with minimal waste, enhancing production efficiency. This precision reduces the need for secondary finishing, saving time and resources. Moreover, the waterjet’s cold-cutting process eliminates heat-affected zones, preserving the material’s integral strength. This is vital for customers as it ensures the highest quality of tools and dies, contributing to seamless operations, extended tool lifespan, and increased productivity. Our waterjet usage underlines our commitment to quality, efficiency, and customer satisfaction, demonstrating our dedication to delivering exceptional tool and die-making solutions.

Simulation

We leverage cutting-edge simulation software to optimize our tool and die manufacturing processes. This technology enables our employees to visualize and refine production processes before implementation, significantly reducing trial-and-error and material waste. By identifying potential errors or inefficiencies in the simulated environment, we ensure the production of superior-quality tools and dies. This is critical for our customers as it guarantees reliable and high-performance products, which in turn enhances their operational efficiency, reduces downtime, and increases productivity. Our use of simulation software contributes to customer satisfaction through improved product quality and cost-effectiveness.

Thermal Analysis

Here at EagleMatic we employ thermal analysis in our tool and die making process to ensure optimal results. By measuring the heat changes within the metal during the manufacturing process, we can identify any potential issues or inefficiencies. This allows for real-time adjustments, ensuring each tool and die produced meets the highest quality standards. The thermal analysis also helps in predicting the behavior of materials under different thermal conditions, thereby enhancing the durability and performance of the tools and dies. Through this method, EagleMatic is able to optimize production, minimize waste, and deliver high-quality products to their clients. Implementing advanced techniques like thermal analysis is crucial for maintaining precision and quality in tool and die manufacturing.

Servo Motor Control

We always suggest incorporating Servo Motors in our tool and die production process, to enhance precision and efficiency. These motors provide superior control over speed, torque, and position, enabling precise and accurate movements during the manufacturing process. The motors’ high-performance characteristics allow for quicker and smoother operations, reducing production time and increasing output. They also contribute to the longevity and durability of the tools and dies, as they minimize wear and tear due to their controlled movements. The integration of Servo Motors into our production process underscores our commitment to quality, efficiency, and technological advancement. The inclusion of Servo Motors is essential for maintaining precision and efficiency in tool and die making.

3-D Laser Scanning

We incorporate 3D laser scanning in our tool and die production to heighten precision of our tooling. This innovative technology captures detailed geometric data by scanning the surface of an object, creating an accurate 3D model. This model is then used to design or reverse engineer tooling. It eliminates the guesswork and potential for human error, ensuring a perfect fit every time. Additionally, it expedites the production process by removing the need for manual measurements. 3D laser scanning plays a key role in our dedication to producing high-quality, precise tools and dies.

In Line Tool Changes

We feature in-line tool changes in our tool and die production process to ensure consistent quality. This sophisticated method enables a seamless transition from one tool to the next without interrupting the production flow, thereby minimizing downtime. It allows for real-time adjustments based on the precision data collected, ensuring each tool and die meets the exact specifications. Through the integration of advanced technologies like Servo Motors and 3D laser scanning, we can swiftly and accurately change tools, which not only accelerates the production process but also significantly reduces the risk of error, resulting in optimum quality and productivity.

4 & 5-axis machining

Custom Made

Data Collection

Waterjet Tooling

Simulation

Thermal Analysis

Servo Motor Control

3-D Laser Scanning

In Line Tool Changes

Case
Studies

AUTOMATED VINYL HOUSE SIDING

BEVERAGE SORTING SYSTEM

AUTOMOTIVE BATTERY COOLING AUTOMATION

At the heart of our operations, we are a team of dedicated tool and die makers, constantly innovating to deliver precision and efficiency to our clients. As premier tooling designers, we possess an intricate understanding of their applications, ensuring seamless production processes. The mastery of our tool makers is evident in the agility with which they navigate the complex manufacturing industry utilizing our state-of-the-art equipment. Our die makers, on the other hand, exhibit their expertise in their craft of building systems. Each die that passes through our production process is a testament to our commitment to quality, bearing the mark of our team’s meticulous workmanship. As a company, we pride ourselves in our ability to understand and respond to our client’s needs, crafting bespoke solutions that reflect our deep-rooted proficiency. Our position as industry leaders is anchored in our core identity as tool and die makers, committed to pushing the boundaries of what is possible in our field.

Tool Makers

Our advanced production methods for tooling significantly contribute to scrap reduction. The precision offered by their waterjet and 4/5 axis machining technology minimizes waste by accurately cutting materials, thereby preserving material integrity and reducing the need for secondary finishing. The application of simulation software and thermal analysis reduces trial and error, ensuring optimal use of materials. In-line tool changes enable real-time adjustments, further minimizing waste. The inclusion of Servo Motors enhances accuracy, reducing excess materials. Lastly, 3D laser scanning provides precise measurements, eliminating guesswork and potential waste. Thus, through these technologies, We optimize material use, thereby minimizing scrap and enhancing production efficiency. Implementing advanced tool and die production methods is crucial for minimizing scrap and enhancing efficiency.

Scrap Reduction

Our tool and die solutions significantly increase repeatability in production processes. The integration of advanced technologies minimizes the possibility of errors, while fully automated systems practically eliminate operator mistakes. The precision of machines, unaffected by fatigue or distraction, ensures consistent task execution. This high degree of precision and consistency translates into superior product quality and heightened customer satisfaction. Thus, the adoption of our tool and die solutions not only streamlines your production process but also promotes a reliable and superior end product, cementing customer trust and satisfaction.

Increased Repeatability

High press tonnage is a significant advantage in our tool and die production process. This high force capacity allows for the manipulation of thicker and harder materials with incredible precision, expanding the range of possible applications. It ensures consistent, high-quality results, even for complex or large-scale projects. High press tonnage also enhances efficiency; a single, powerful press can often achieve what might otherwise require multiple, less forceful actions. Ultimately, this leads to quicker production times, less material wastage, and a substantial increase in overall productivity, solidifying our reputation for superior tool and die solutions.

High Press Tonnage

Maintaining tight tolerances in our tooling is a top priority. Our commitment to precision engineering ensures that each product we manufacture adheres to the exact specifications of our clients. This focus on tight tolerances not only underscores our dedication to quality but also eliminates issues such as part misfit or malfunctioning, leading to superior performance and extended tool life. Our state-of-the-art equipment, meticulous quality control procedures, and skilled workforce collaborate to achieve these precise standards, ensuring consistently high-quality output and customer satisfaction. This precision is ingrained in our production process, reinforcing our reputation for excellence.

Tight tolerances

Our in-house design and engineering team has over 100 years of experience in creating intricate custom automation processes from a blank slate. We take pride in offering creativity and precision to solve any of your production needs.

Having an in-house design team for creating tool and die systems provides several benefits to our customers. Firstly, it ensures seamless coordination from the conceptualization to the production phase, resulting in quicker turnarounds. Secondly, our designers’ intimate knowledge of our manufacturing capabilities allows for innovative, tailored solutions that cater specifically to each customer’s needs. Moreover, any modifications or adjustments can be handled swiftly and efficiently, without the need for prolonged communications with external parties. This ultimately means better quality control, cost-efficiency, and a more personalized service, which translates to superior customer satisfaction.

IN-HOUSE-DESIGN

When needed, we integrate vision systems, robotics, and more from industry-leading manufacturers. Our strategic selection of vendors allows us to offer a variety of top-quality products to integrate into a custom solution for you. By collaborating with renowned tool and die makers, we ensure the incorporation of cutting-edge technology and precision engineering into our solutions. This synergy between advanced automation and expert tool and die-making enhances the performance and efficiency of our integrated systems, setting us apart in the market.

Our strategic selection of vendors allows us to offer a variety of top-quality products to integrate into a custom solution for you. Partnering with industry leaders such as Cognex, Festo, Allen-Bradley, Hubbell, FANUC, Rexroth, Turck, Keyence, Lamina Technologies, and Mitsubishi, we ensure that only the finest components are utilized in our integrated solutions. This commitment to excellence and precision is what distinguishes us as a trusted provider of tool and die-making solutions and integrated systems.