The cutting edge

The work has changed, but the need for people hasn’t

At first glance, the factory runs smoothly. Screens are green, machines hum, projects move along. Automation has already closed many gaps by connecting systems and reducing manual work. And yet, there will always be moments when production stands still, waiting for the few who understand how those systems work together. This is when another reality becomes visible. The promise of automation is to provide reliability. To move away from firefighting and toward proactive guardrails. That shift comes with its own set of challenges because the way we view the process has changed as well. We’ve moved from simply doing the work to needing in-depth understanding of sophisticated machines and complex machining methods. In that sense, the skills gap is also a natural push toward upskilling and reskilling, and an opportunity to strengthen the link between people and technology. At the same time, experience is leaving the workforce Senior experts are retiring, taking with them knowledge that cannot be successfully replicated without meaningful human-to-human interactions. Their instructions are not dry facts but often based on instincts and innate knowledge on how a material behaves under certain conditions. Recognizing a problem before it appears in the data or understanding how adjustments made upstream affect results downstream. This kind of knowledge is learned through years of practice and once gone, it cannot be replaced quickly. Outside the factory walls, perceptions are forming Younger workers often see manufacturing as distant or opaque. Not outdated, but hard to read. What is it that we’re making? What does it do? Where does it go? Why does this matter? The work itself can feel disconnected from its outcome. Components disappear into larger systems, effort becomes procedural, and that feeling of pride in your work seems faint, almost imperceptible when the day moves so fast. When people can’t see what their work contributes to and aren’t seen as an integral part of progress, motivation fades. This dynamic affects recruitment, retention, and continuity at once Some manufacturers have started to respond by changing how they think about learning. Training is no longer treated as a standalone activity or a periodic intervention. It happens alongside production — close to machines, anchored in real problems and real people. Senior specialists are given time and structure to share what they know, receiving attractive incentives to teach the next generation even after retiring. Many of them find satisfaction and personal fulfillment in sharing their knowledge with others and on a deeply human level, it’s a beautiful chapter at the end of a long, dynamic career. Not a book that closes abruptly. And this is not just to keep things moving. It’s done with the pause, purpose, and passion for the craft that the manufacturing industry thrives on. If you want to explore this perspective in depth (including data, real-world examples, and practical steps for defying the skills gap) download our free white paper The precious human resource . Download it here The work has changed, but the need for people hasn’t The work has changed, but the need for people hasn’t The work has changed, but the need for people hasn’t At first glance, the factory runs smoothly. Screens are green, machines hum, projects move along. Automation has already closed many gaps by connecting systems and reducing manual work. And yet, there will always be moments when production stands still, waiting for the few who understand how thos... Human Resource Needs Discusses the continuous need for skilled people in automated manufacturing. Explores the evolving role of humans in automated manufacturing. Highlights the skills gap, the importance of upskilling and knowledge sharing, and challenges with youth perceptions of the industry. chevron_right

Leave your turning center alone: This is automatic tool change

When your machine stops waiting for you and production keeps moving even while you step away, something fundamental shifts on the shop floor. This is the turning point in turning automation. If you walk through the Sandvik Coromant factory in Gimo (Sweden), you quickly learn to stay alert. The floor is busy, the machines are focused on their work, and the small automated guided vehicles (AGVs) can appear at your side without a sound. Each one is named after a Lord of the Rings character, so it’s not unusual to see the mythical Gandalf or steadfast Frodo rolling past on their way to pick up the next batch of materials. We were there to watch automatic tool change (ATC) in action, running steadily in the middle of all this activity. It fits naturally into the pace of the place: consistent, predictable, and designed to keep production moving without adding stress to the team. Step behind the scenes with Bo Hammarberg and Niklas Larsson, Product Manager and Manufacturing Engineer at Sandvik Coromant, and see automatic tool change in action as they talk about the challenges it solves and the shift it brings to turning. In turning centers, efficiency evolves by spotting patterns and acting on them with the right combination of knowledge and tools — but one of the most significant barriers to productivity has always been the moment everything must stop. When the tool wears out, the operator steps in, the machine goes idle, and valuable minutes slip away. Across the industry, this pattern repeats thousands of times a day: small interruptions that accumulate into major losses. For years, this has been the accepted compromise in turning and for many manufacturers, it has become a critical bottleneck, one that the industry no longer has the workforce to absorb. When skilled labour becomes scarce, downtime becomes expensive In one case, a U.S. customer built a new production unit with 40 machines and needed 100 trained operators to run them. They could find just five.  This shortage reshapes how manufacturers think about time, utilization, and risk. Manual tool changes require skill, attention, and availability — three things in increasingly short supply. With every routine manual change or delayed swap, machine utilization drops and cost per part rises. “The skills gap is here and now.” — Bo Hammarberg This is the landscape Sandvik Coromant stepped into when developing automatic tool change for turning centers, closing the final gap in automation that has held turning back for decades. A simple idea with transformative impact “Turning machines have always struggled with the number of tools,” Niklas explains. “Since you only have twelve positions on a turret, you are often very limited.” ATC effectively solves this limitation by combining an external tool stand with robot-managed tool change. Turning centers can now access up to 40 additional tool positions, expanding capability without altering the machine footprint. Tools are monitored automatically, swapped autonomously, and prepared by technicians outside the machine while it keeps cutting. The system is built on machine-adapted clamping units with a Coromant Capto interface, ensuring stable tool changes and compatibility across setups. “The biggest technical advantage is machine uptime.” — Niklas Larsson “Now we can change cutting tools both on static turning tools as well as rotating tools, which no one else can do in the industry today on turning centers,” Bo says. While convenient, the true value lies in the ability to machine continuously, enabling unmanned or lights-out production. “With multiple sister tools, you can run the machine unmanned for long periods,” Niklas says. Using VERICUT, the entire automatic tool change sequence can be simulated and verified virtually before it ever reaches the shop floor, adding another layer of certainty to unmanned production. Automation that protects both performance and people The benefits extend beyond productivity. Turning centers are notoriously tight spaces — cramped, sharp, difficult to maneuver. Operators risk cuts and bruises during manual tool handling, especially when rushing between machines. “With ATC, that risk disappears,” Bo explains. “If you change the tools with the robot, you put safe distance between yourself and potential injury.” Safety is fundamental to Sandvik Coromant and reflects its commitment to manufacturing wellness, where resilient processes, sustainable operations, and healthier working environments form the foundation of progress. “We don’t make machines. We make them better.” — Bo Hammarberg For decades, turning has lagged behind milling and multitask machines in automation maturity. Even highly advanced systems relied on manual tool changes — a missing piece that prevented full lights-out manufacturing. “Automatic tool change is the next step in the machine development when it comes to turning centers,” Bo says. “And now we have come to a breakthrough, where you can have automatic tool change as you have on all other machine concepts today.” The dedication invested in this project is not to be underestimated. “When I started working here three years ago, I was handed this project,” Niklas recalls. “Here we are now, with machines fully up and running. I’m extremely proud.” Machines evolve and we make them better ATC marks a shift in how turning centers work. By taking over a task that once demanded time, focus, and experience, it frees skilled people to work where their judgment actually matters. The machine keeps cutting; the operator keeps creating value. Its impact also represents two habits that define a future-ready workshop: embracing new technology and automating for success. Both reduce the pressure on scarce expertise and create room for clearer thinking, smarter decisions, and steadier production. Remove the repetitive work, and consistency follows. Automate the tool change, and the machine finally runs the way it was built to without unplanned breaks and surprises. This is how reliability becomes part of daily progress, and how manufacturing wellness takes shape on the shop floor. “As a mechanical engineer, I love new technology… This is the future.” — Niklas Larsson With automatic tool change for turning centers, the future is constantly on the move: running, cutting, and producing with minimal downtime and maximum potential for productivity. Leave your turning center alone: This is automatic tool change Leave your turning center alone: This is automatic tool change Leave your turning center alone: This is automatic tool change When your machine stops waiting for you and production keeps moving even while you step away, something fundamental shifts on the shop floor. This is the turning point in turning automation. Automatic Tool Change This article explains how automatic tool change for turning centres increases machine uptime, enables unmanned production and improves operator safety by automating tool handling. Overview of Sandvik Coromant’s automatic tool change for turning centres, showing how robot-managed tool handling increases uptime, enables lights-out running and improves safety by moving tool changes outside the machine envelope. chevron_right

This is how you turn productivity insight into sustainability impact

The data is clear: sustainability is now a business mandate. Fictiv’s 2025 State of Manufacturing report shows that 91% of manufacturers have sustainability governance in place, and 95% say sustainable practices are essential. Energy costs, regulations and customer expectations are driving a fundamental shift in how workshops operate. Yet even with these commitments, most factories still lack one crucial capability: the ability to see their true energy consumption and CO footprint component by component, operation by operation. The Sustainability Analyzer changes that. Developed as an extension to the long-established Productivity Analyzer, it brings energy, emissions and cost data directly into everyday machining analysis. Instead of guessing where inefficiencies are hidden, manufacturers can now see the full picture right down to the component. Why energy visibility is crucial Today’s CNC machines consume more power than ever. Idle energy, spindle load, cooling systems, and toolpath choices all contribute to a workshop’s environmental footprint. Even small inefficiencies compound into significant cost and emissions over a year, yet many manufacturers still have no system to measure them. That gap in visibility is exactly where the Sustainability Analyzer creates value. By combining spindle energy data, idle power consumption, local electricity pricing and regional CO intensity, it turns complex production data into clear, actionable insights. What the Sustainability Analyzer brings to your shop floor The white paper breaks down how the tool creates a unified view of both productivity and sustainability, enabling manufacturers to: Understand energy usage per component Track annual CO emissions linked to machining Identify where savings can be unlocked Validate tooling or process changes with real numbers Support decisions that align productivity, cost and climate targets In other words, it helps manufacturers transform sustainability from a broad ambition into something measurable, manageable and tied directly to performance. Why it matters now From the EU’s Carbon Border Adjustment Mechanism (CBAM) rollout to increasing investor pressure, environmental performance is becoming a competitive differentiator. Manufacturers who cannot quantify their impact will struggle to meet new expectations while those with the right data can move faster, invest smarter and demonstrate real progress. Tools like the Sustainability Analyzer offer exactly that advantage. Want the full picture? The Sustainability Analyzer white paper focuses on minimizing manufacturing’s environmental impact with data-driven insights and explores: The industry pressures reshaping sustainability in machining Why energy data is becoming a core business metric How the Sustainability Analyzer works and what it reveals How manufacturers can use it to accelerate both productivity and emissions performance Read the full white paper to see how data-driven insights can reshape your approach to sustainability. Highlights Minimizing emissions and climate impact based on data with Sustainability Analyzer The analyzing tool that helps customers reduce their energy consumption and carbon emissions based on data This is how you turn productivity insight into sustainability impact This is how you turn productivity insight into sustainability impact This is how you turn productivity insight into sustainability impact The data is clear: sustainability is now a business mandate. Fictiv’s 2025 State of Manufacturing report shows that 91% of manufacturers have sustainability governance in place, and 95% say sustainable practices are essential. Energy costs, regulations and customer expectations are driving a fund... Sustainability Analyzer Overview This article explains how the Sustainability Analyzer uses machining data to measure energy use, emissions and costs so manufacturers can link productivity gains to sustainability performance. Explains how the Sustainability Analyzer integrates energy, emissions and cost data into machining analysis so manufacturers can quantify environmental impact, validate process changes and align productivity with sustainability targets. chevron_right

Trajectory Optimization in Face Milling Operations

Face milling is a fundamental machining operation used to generate flat surfaces with high precision. Traditionally, it has been optimized based on parameters such as cutting speed, feed rate, and depth of cut. However, the trajectory followed by the tool also plays a crucial role in the overall efficiency of the process, both in terms of energy consumption and the usual effects on tool life, productivity, and surface quality. Types of trajectories in Face Milling Thanks to the development of CAM systems, we now have a wide range of options for machining trajectories for roughing and finishing surfaces. Among all these options, there is a main difference: some operations keep the tool always in contact with the workpiece, while others include idle (non-cutting) movements. We can classify them into four basic categories: Unidirectional : The most basic and easiest operation to program. The tool works with linear trajectories in the same direction and returns without cutting. Acceptable surface finishes are obtained, but if direct entry is used, it can affect tool life and increase the total cycle time. Zig-zag (bidirectional) : Linear movements with the tool moving in both directions, reducing idle times, but with negative effects on the resulting surface quality. Managing the changes in direction can affect tool life. Spiral: Either towards or from the inside of the workpiece, it allows for continuous cutting with controlled engagement, offering good surface finishes and good control of tool life while reducing machining times. Adaptive and trochoidal : Trajectories that optimize tool-material contact by maintaining controlled radial engagement, improving surface quality. They usually include small idle movements in hard-to-reach areas but aim to keep the tool in contact as much as possible. They are highly recommended for difficult-to-machine materials. Each of these trajectories has different implications in terms of machining time, workload, energy consumption, and heat generation. CO Emissions In this article, we will mainly address the energy effect of trajectories by comparing those that maintain constant contact between the tool and the workpiece with those that, due to their configuration and different orientation, involve idle (non-cutting) movements. To illustrate this comparison, we will use, an alternative unidirectional trajectory and a spiral trajectory from the outside, both under the same cutting conditions, and compare the energy consumption of both options. Subsequently, we will compare both trajectories with improved cutting conditions. We can calculate the power consumed on different materials, selected from a wide data base, and using specific combination of tools and inserts geometries, during a milling operation using “ToolGuide,” available at this link. ToolGuide For a face milling operation with the CM345 ref 345-050Q22-13H Z6, with inserts 345R-1305M-PM 1230, on a 32CrMoV12-28 P3.0.Z.AN steel workpiece with 230 Hb, we will start from these two cutting conditions, which will give us two different cutting power consumptions. During rapid movement at speeds of 5,000 to 10,000 mm/min (without cutting load) on a conventional 5-axis CNC machine with a maximum power of 40 kW, typical energy consumption ranges between 4 and 7 kW. For our example, we will use 5.5 kW as the calculation value. The components that make up this basic machine consumption are: Software and electronic equipment of the machine. Machine movement, plus the rotation of the cutting spindle itself. The higher the feed rate, the greater the energy demand. Machine movement, plus the rotation of the cutting spindle itself. The higher the feed rate, the greater the energy demand. This range is useful for estimating energy consumption during rapid positioning phases or movements between operations, especially in intensive machining cycles. Case Studies Case 1: Unidirectional vs. Spiral trajectories. In a face milling operation on a 250x250 mm steel plate, two trajectories were compared: unidirectional and spiral. The spiral trajectory has a total cutting length of 1,250 mm, which is equivalent to 38.26 seconds of cutting time. In the unidirectional trajectory, there are 5 paths of 300 mm each, and we must add 4 return paths with a table feed of 7,500 mm/min. This allows the total machining to be completed in 45.918 9.6 55.51 seconds, an increase due to the non-cutting return time. The cutting power is 16.7 kW, and the power consumed during idle movements is 5.5 kW. Therefore, the total energy consumption during the cutting time is 0.2276 kWh for the unidirectional trajectory and 0.1774 kWh for the spiral trajectory. The graph provides a clearer view of the kWh savings. Comparison between unidirectional and Spiral trajectories Case 2: Comparison between original and higher Fz0,4 cutting conditions. We have already seen how idle movements of the machine affect energy use. Now, if we take our second set of cutting conditions, with a feed per tooth of 0.4 mm, we can observe the effect of increased cutting parameters on both energy consumptions. The working power will increase to 18.1 kW, but the cutting time for the spiral trajectory will decrease to 33.48 seconds. In the unidirectional operation, the cutting time will be 40.17 9.6 50.07 seconds. Therefore, the new total energy consumption during cutting time is 0.2166 kWh for the unidirectional trajectory and 0.1683 kWh for the spiral trajectory. This is a counterintuitive result, cause with higher cutting power, we obtain lower energetic total consumption thanks to cycle time reduction. Increase feed on unidirectional trajectories effect Increase feed on unidirectional trajectories effect Energy and CNC Machine Cost Analysis by Region The following table presents a comparative analysis of energy costs, CNC machine hourly rates, and average CO emissions per kilowatt-hour (kWh) across different regions. This data is useful for evaluating the environmental and economic impact of CNC operations globally. And here are the data for all the cases studied. kwh y CO2 emissions and cost based on average data for all regions. Conclusion The choice of trajectory in face milling operations not only affects quality and productivity but also has a direct impact on process sustainability—energy costs, direct machine costs, and CO emissions into the atmosphere. Adopting optimized trajectories through advanced CAM software allows you to: Improve energy efficiency. Reduce tool wear. Decrease CO emissions. Lower direct machining cost and increase productive capacity. For CO consumption, the reduction is 26% when comparing the unidirectional trajectory with Fz0.35 to the spiral trajectory with Fz0.4. This also results in a 40% economic reduction . In an industrial environment increasingly focused on sustainability, these technical decisions can make a significant difference. Selecting tools that allow us to work at the highest cutting conditions will achieve both direct economic savings and reductions in CO emissions. Alvaro Ruiz Global product solution specialist Milling Trajectory Optimization in Face Milling Operations: Impact on Costs, Energy, and CO Emissions Face milling is a fundamental machining operation used to generate flat surfaces with high precision. Traditionally, it has been optimized based on parameters such as cutting speed, feed rate, and depth of cut. However, the trajectory followed by the tool also plays a crucial role in the overall efficiency of the process, both in terms of energy consumption and the usual effects on tool life, productivity, and surface quality. Trajectory Optimization in Face Milling Operations: Impact on Costs, Energy, and CO Emissions Trajectory Optimization in Face Milling Operations: Impact on Costs, Energy, and CO Emissions Face milling is a fundamental machining operation used to generate flat surfaces with high precision. Traditionally, it has been optimized based on parameters such as cutting speed, feed rate, and depth of cut. However, the trajectory followed by the tool also plays a crucial role in the overall ... Face Milling Trajectories The article analyses how different face milling trajectories affect energy use, CO emissions, cycle time, and cost, using practical case studies comparing unidirectional and spiral tool paths. Overview of face milling tool paths and how trajectory choice influences cutting time, energy demand, machine cost, and CO emissions, including a quantitative comparison of unidirectional and spiral strategies under different cutting conditions. chevron_right

Mastering high-volume hole making

Overcoming common drilling pain points with CoroDrill DE10 High-volume drilling requires precision, efficiency and reliability to meet demanding production schedules and maintain cost-effectiveness. For manufacturers, these requirements often pose challenges, such as ensuring tool longevity, achieving consistent hole quality and minimizing downtime. So, what’s required to achieve more efficient hole drilling in an increasingly competitive environment? Here, Mikael Carlsson, Global Product Specialist for Indexable Rotating Tools at Sandvik Coromant, explains how a new drilling innovation could reinvent high volume hole making. Several shifts in manufacturing trends are increasing the demand for high volume drilling. Producing electric vehicles (EVs), for example, requires drilling thousands of precise holes in battery enclosures and thermal management systems, intensifying the need for reliable, scalable solutions. Similarly, renewable energy sectors, such as wind and solar power, rely on high-volume drilling for producing key components like wind turbine shafts and solar mounting systems, where accuracy and durability are paramount. In industries where efficiency and reliability are non-negotiable, finding solutions that balance these demands is critical. Drilling down the challenges High-volume hole making often reveals challenges that can be underestimated, even by experienced manufacturers. Many already recognize the critical importance of tool wear and cycle times, but it is the hidden complexities of high-speed and high-penetration operations that can profoundly impact productivity and operational efficiency. Take, for example, thermal and mechanical stresses encountered during the drilling of thousands of holes — especially in typically more challenging materials like hard steels and heat resistant super alloys. These forces can lead to accelerated tool fatigue, burr formation or even deformation of the workpiece. Such challenges go beyond tool durability. They involve understanding the interplay between the tool's geometry, coatings and material composition with the specific characteristics of the workpiece. Effective heat dissipation, resistance to microfractures and the ability to maintain edge sharpness over prolonged use are all crucial factors for ensuring consistent quality across extended production runs. Another consideration is the cost impact of seemingly minor inefficiencies, such as setup or tip changes. In large-scale operations, for instance, even a small amount of downtime per shift — whether due to recalibrating machines for a new tool or replacing worn-out tips — can accumulate into substantial productivity losses. These inefficiencies highlight the importance of streamlined solutions, such as systems designed for quick setup, precise alignment and easy tool changes. Additionally, eliminating unnecessary steps in the drilling process can drive significant time and cost savings. For example, tools that remove the need for pilot holes or pre-setting equipment can drastically reduce cycle times and minimize the reliance on operator intervention, thereby increasing overall process stability and throughput. Addressing these pain points with thoughtful planning and optimized tooling strategies is essential for manufacturers striving to meet the demands of high-volume production without compromising on quality or efficiency. A streamlined approach Introduced by Sandvik Coromant in March 2025, CoroDrill DE10, an advanced exchangeable-tip drill designed for high-volume hole drilling, aims to address these drilling challenges. CoroDrill DE10 is shown to boost productivity while streamlining operations, due to its advanced -M5 tip geometry. This innovative design achieves an ideal balance between high feed rates and precise penetration, enabling the tool to deliver exceptional performance across diverse materials. From steel alloys to stainless materials, CoroDrill DE10 can ensure consistent hole quality while also minimizing the risks of burr formation or workpiece deformation. A crucial feature of CoroDrill DE10 is a patented pre-tension clamping interface, which combines familiar design with enhanced security. The interface enables fast and easy tip changes without spare parts, ensures reliable drilling at high feeds and speeds, delivers superior clamping strength and achieves straighter holes with tighter tolerances. It also extends drill body life, making CoroDrill DE10 the most robust exchangeable-tip drill of its kind. Furthermore, CoroDrill DE10 also eliminates the need for pilot holes to further streamline workflows and reduce cycle times and inventory complexity. Its robust design supports extended tool life, with more tips per tool body, which ultimately drives down the cost per hole. As a plug-and-play solution, CoroDrill DE10 integrates effortlessly into existing setups, making it a practical upgrade for manufacturers looking to enhance productivity without overhauling their systems. It also integrates seamlessly with digital machining systems through Sandvik Coromant's CoroPlus platform. This compatibility provides operators with precise cutting data and real-time performance insights, so parameter settings can be optimized and tailored to specific materials and applications. Operational and cost-saving benefits Several success cases have highlighted how CoroDrill DE10 drastically improves productivity in high volume drilling. In testing conducted in Italy, CoroDrill DE10 demonstrated significant performance advantages over a competing tool while drilling AISI316L stainless steel. The case involved 52 mm through and blind holes, using emulsion coolant at 70 bar. CoroDrill DE10 achieved a remarkable 57% increase in productivity and 43% longer tool life compared to its competitor. The tool also delivered excellent hole surface quality, consistent chip control and sound-level performance aligned with expectations. The tool’s robust design and advanced -M5 tip geometry ensured reliability and repeatability — and both were key factors for the high-value components in this application. With a higher feed rate, extended tool life and reduced need for downtime, CoroDrill DE10 proved to be a cost-effective, efficient and sustainable solution for high-volume drilling in challenging materials. In another case, an automotive manufacturer faced issues with high cutting forces deforming its drill bodies, specifically while machining gearbox housing components from 47CrMo4 alloyed steel. This issue led to tool failures and increased costs. Instead, switching to CoroDrill DE10 resolved these challenges. Using a feed rate of 0.35 mm/rev at a depth of cut of 2.5 times the drill diameter, the tool delivered a 17% productivity boost. As in other applications, CoroDrill DE10's robust design and patented pre-tension clamping interface ensured exceptional accuracy, extended tool life and minimized downtime. These examples demonstrate how CoroDrill DE10 meets industry needs while offering significant operational and cost-saving benefits. High-volume hole-making demands precision, durability and efficiency, making it essential for manufacturers to overcome its challenges to achieve greater productivity and remain competitive. With its advanced features, tools such as CoroDrill DE10 offer a new perspective on drilling, and a strategic solution for the future of manufacturing. Learn more about CoroDrill DE10 Sandvik Coromant info.coromant@sandvik.com Mastering high-volume hole making Mastering high-volume hole making High-Volume Hole Drilling This article discusses high-volume drilling techniques and challenges, highlighting solutions like CoroDrill DE10 for improved efficiency. Exploring efficient techniques for high-volume drilling, addressing challenges in precision and durability. CoroDrill DE10 offers innovative solutions with extended tool life and streamlined operations to meet competitive manufacturing demands. chevron_right

Unlocking the benefits of multi-material drills

Versatile drilling offers a key to more productive manufacturing In January 2025, the World Economic Forum reported that facilities identified as part of its Global Lighthouse Network are achieving remarkable productivity gains of 70%, while simultaneously reducing energy costs by 40% and time to market by 40%. Lighthouses aside, how can all manufacturers raise their productivity, without increasing costs? Here, James Thorpe, Global Product Manager for Hole Making and Composite Machining at Sandvik Coromant, explains how a new drilling tool can enhance manufacturing production goals for multi-material applications. Beyond the Lighthouse facilities, manufacturers across the globe are increasingly tasked with producing parts from a diverse array of materials — from hardened steels and composites to softer metals and plastics — all while striving for uncompromising precision and efficiency. Addressing these challenges head-on requires tooling solutions that not only push the boundaries of traditional drilling capabilities but also streamline operations in an increasingly competitive market.  Overcoming pain points   Drilling is a fundamental yet technically demanding operation in modern manufacturing. One of the most persistent challenges involves material variability. Manufacturers often work with a wide range of materials, from tough hardened steels to lightweight but ductile metals. Each material presents unique difficulties —hardened steels can cause excessive tool wear, while softer metals may deform under drilling forces.  Heat generation and tool wear are also significant concerns in drilling operations. High cutting speeds, prolonged machining cycles and demanding material compositions contribute to excessive heat buildup. This not only accelerates tool degradation but also impacts machining accuracy, leading to surface defects and deviations from required dimensions. Effective heat management solutions, both in tool design and machining strategies, are therefore critical for extending tool life and improving component quality.  Another key challenge is chip evacuation. In deep-hole drilling or high-feed applications, inefficient removal of chips can lead to clogging, increased heat generation and even tool failure. Drill flutes must be designed to facilitate smooth and consistent chip evacuation, preventing operational disruptions and maintaining stable machining conditions.  Process stability is equally essential for precision manufacturing. Accurate hole positioning and straightness are critical for high-quality components used in sectors such as aerospace and automotive. Any deviation can compromise the functionality of the final product, leading to costly rework or component rejection. Achieving and maintaining stability requires a combination of robust tool geometry and optimized machining parameters.  Lastly, manufacturers face growing pressures to adopt sustainable and cost-effective production practices. Reducing waste, extending tool life and minimizing energy consumption are priorities as companies strive to meet both economic and environmental goals. These factors drive the demand for drilling tools that deliver superior performance while lowering the total cost per part.  A drill for all materials    To boost productivity and maintain cost-efficiency, there’s a growing need for versatile drills that can handle multiple materials, eliminating the need for frequent tool changes while lowering tooling costs. Advances in coatings and tool design enable these multi-material drills to perform well without compromising quality, offering both cost savings and improved sustainability.  A prime example of this is CoroDrill Dura 462, which is specifically engineered to enhance performance across a wide range of materials. Featuring a fine-grained cemented carbide substrate, CoroDrill Dura 462 offers exceptional wear resistance and reliability with a well-controlled microstructure that ensures consistent results, even when working with challenging materials like hard metals or ductile alloys. This makes it an invaluable tool for manufacturers seeking uniform precision and stability, no matter the material composition of their components.  CoroDrill Dura 462’s geometry is designed with versatility in mind. The tool’s point design significantly reduces cutting forces, improving positional accuracy, especially in high-tolerance applications. The drill’s clearance angles reinforce point strength, while its single-margin configuration helps minimize heat buildup, further enhancing tool stability and overall performance.  Further enhancing its performance is Sandvik Coromant’s patented Zertivo 2.0 PVD coating, which, alongside the fine-grained carbide substrate, provides superior wear resistance and enables high-speed drilling while maintaining process stability.  Benchmarking results have shown the tool’s clear competitive advantage. In one customer case, CoroDrill Dura 462 increased productivity by 110% and extended tool life by 36%. Another case demonstrated an 85% productivity gain and a tool life that more than doubled compared to a low-cost competitor.  While WEF's Lighthouse facilities guide the industry toward more efficient manufacturing, manufacturers need the right tools to navigate the complexities of multi-material production. By adopting versatile solutions that tackle material variability, heat management and process stability, they can chart a course toward significant productivity breakthroughs and operational excellence.  Learn more about CoroDrill Dura 462 Sandvik Coromant info.coromant@sandvik.com Unlocking the benefits of multi-material drills Multi-material Drill Benefits Learn how multi-material drills improve productivity and efficiency in manufacturing. Explores the advantages of using multi-material drills to enhance manufacturing productivity and efficiency, addressing challenges like material variability, heat management, and chip evacuation. chevron_right

Master the unmachinable

Machining composite materials remains one of manufacturing’s toughest challenges. Abrasive fibres, layered structures and sensitivity to heat and vibration often result in unpredictable cutting behaviour, delamination and accelerated tool wear. Their poor thermal conductivity means composites are usually machined dry, making heat even harder to control. So what does it take to machine these materials more efficiently and with greater confidence?  Here, our experts in solid carbide end milling tools at Sandvik Coromant explain how. Composite materials, especially carbon and glass fibre reinforced plastics (CFRP/GFRP), impose unpredictable cutting forces that can vary dramatically depending on fibre direction, resin content and manufacturing method. Conventional tools can dull quickly on hard fibres, while excessive cutting forces or improper geometries often cause delamination or leave uncut fibres. The result is inconsistent performance and elevated scrap rates. The serrated router,  CoroMill Plura composite 2P350 , was developed to address these challenges directly, offering sharper, more durable edges and a geometry optimized for stable, low-defect machining. This is a significant step forward in stability, quality and process security when working in demanding composite applications. Patented dual cutting mechanism A crucial feature of CoroMill Plura Composite 2P350 is its patented serrated geometry, designed to deliver a balanced, scissor-like dual cutting action. This coordinated mechanism effectively clamps and shears the fibres, reducing cutting forces and counters the tendency of composite layers to split and delaminate or produce uncut fibres. The geometry balances cutting loads across all flutes, preventing any single tooth from taking excessive force. This results in lower and more consistent cutting forces compared to traditional routers, protecting both the tool and the workpiece. Reduced cutting forces also contribute to better surface finish and less risk of delamination or uncut fibres. By disrupting harmonic vibrations, the geometry also contributes to a more stable and quieter machining process. The controlled cutting action not only improves surface integrity but also enables reliable one-pass machining, supporting both process security and a more comfortable sound level in the workshop. A grade for abrasive composite environments The introduction of grade O2AD marks a significant breakthrough for tool life and long-term stability. Composite materials are extremely abrasive, and tools often lose sharpness quickly if not specifically engineered for these conditions. Grade O2AD is developed specifically to combat these challenges, featuring an optimized CVD diamond coating and a tailored substrate that enables great adhesion between the two. The synergy between the coating and the substrate helps maintain excellent edge-line sharpness for optimal cutting action, ensuring excellent abrasive wear resistance, longer tool life, more predictable performance and less frequent tool changes. Internal tests and customer evaluations show that grade O2AD can double the tool life compared to the previous grade O12M, delivering clear gains in productivity and cost efficiency. Performance in aerospace and beyond CoroMill Plura composite 2P350 is particularly well-suited for the aerospace industry, where composite components must meet strict structural and dimensional requirements. The tool has shown strong performance when machining fuselage frames, wings, stabilizers, spars, ribs, floor beams and other critical structures. The tool’s reliable behaviour across slotting, ramping and edging operations contributes to a more predictable machining process with less scrap and rework, which is especially valuable in high-value production environments. Adding the ability for one-pass machining in these operations, it contributes to fewer secondary operations. Simultaneously, the large flute volume enables efficient chip evacuation and high material removal rates, boosting productivity.  Beyond aerospace, industries such as automotive, defence, space and nautics benefit from the tool’s controlled cutting and consistent results, making this tool a versatile option for a broad range of applications.  Beyond aerospace, wider industries such as automotive benefit from the tool’s controlled cutting and consistent results, making this tool a suitable option for a broad range of industry segments and applications. The full portfolio CoroMill Plura composite 2P350 with grade O2AD represents a major advancement in composite machining tooling. Through its patented cutting geometry, optimized diamond coating and proven performance across demanding applications, it provides the process security and productivity needed to machine one of the industry's most challenging materials.  For even more specialised composite operations, CoroMill Plura composite 2P350 is supported by a wider portfolio. CoroMill Plura composite 2P460 compression router is ideal for components with woven glass layers on both sides, providing excellent vibration control in thicker materials through its overlapping flute design. For finishing operations, CoroMill Plura composite 2P050/2P051 low helix routers enable smooth, burr-free edges in composites and CFRPs, with right/left helix options for improved fixture stability and high-feed capability.  Together, these tools form a complete portfolio designed to help manufacturers achieve consistent, high-quality results across the full spectrum of composite machining challenges. Solid carbide end mill for composite machining CoroMill Plura composite Machining composite materials is a battle of unpredictable forces, heat sensitivity and rapid tool wear. For successful machining, sharp and controlled cutting is required to avoid delamination and vibration. Sandvik Coromant info.coromant@sandvik.com CoroMill Plura Composite Master the unmachinable Machining composite materials remains one of manufacturing’s toughest challenges. Abrasive fibres, layered structures and sensitivity to heat and vibration often result in unpredictable cutting behaviour, delamination and accelerated tool wear. Their poor thermal conducti... Composite Machining Control This article explains how CoroMill Plura composite tools improve process security, tool life and surface quality when machining abrasive CFRP and GFRP components in aerospace and other sectors. Overview of CoroMill Plura composite 2P350 solid carbide routers, their dual cutting geometry, O2AD diamond-coated grade and application performance in abrasive CFRP/GFRP machining across aerospace and other industries. chevron_right

Productivity meets sustainability

The Winning Combination with New CoroMill Face and Shoulder Milling Cutters In today’s competitive industrial landscape, performance, cost efficiency, and environmental responsibility are non-negotiable. That’s why CoroMill  milling solutions have become the gold standard for excellence—delivering superior results in the most demanding operations, from roughing to finishing, across all material types, especially ISO P, M, S, and K. Now, discover the latest innovations for face and shoulder milling: CoroMill MS20, CoroMill MS40, and CoroMill MS60. CoroMill  MS20 - Your go-to for perfect 90 shoulders Building on the legacy of our multi-optimized CoroMill  390,  CoroMill  MS20  is now the ultimate choice for flawless 90 shoulders. Engineered for exceptional dimensional accuracy – even in repeated passes – it ensures optimal chip control and unmatched reliability. Its versatility (face milling, pocketing, grooving, linear and helical ramping, plunging) simplifies tool management and reduces overall consumption. CoroMill  MS40 and CoroMill  MS60 - The perfect partners to CoroMill 490 Our flagship CoroMill  490 remains the universal solution for shoulder milling. But when your operations demand more, CoroMill  MS40 and CoroMill  MS60 step in: CoroMill  MS40 : Designed for repeated passes and wall machining, this tangential concept delivers rigidity, process security, and predictable tool life. With four cutting edges per insert, it maximizes chip removal and stability – even in high-intensity cycles. CoroMill  MS60 : The smart choice for roughing and semi-finishing. Featuring six cutting edges per insert and a unique reversible triangular design, it slashes cost per edge and optimizes carbide usage – helping you cut costs while reducing environmental impact. Choosing the right concept is easy with  CoroPlus  ToolGuide . This online service gives you more than cutting data – it delivers confidence. CoroPlus  ToolGuide — More than just cutting recommendations In just a few clicks, you’ll get an optimized, ready-to-use solution that combines technical performance, time savings, and a reduced carbon footprint.  CoroPlus  ToolGuide  offers: Smart selection of the best Coromant solutions for your material and operation.  Cutting conditions validated for each tool.  Environmental impact calculations: power consumption and CO emissions for responsible decision-making.  Take control of your milling operations today With  CoroMill  MS20 ,  CoroMill  MS40 , and  CoroMill  MS60  cutters, you’re not just choosing tools – you’re investing in  higher productivity, lower costs, and a smaller environmental footprint . Supported by  CoroPlus  ToolGuide , you’ll enjoy fast selection, optimized cutting parameters, and precise energy impact calculations. Sustainable performance starts now. Are you ready to make the switch? Sandvik Coromant info.coromant@sandvik.com Milling Productivity meets Sustainability Productivity meets sustainability The Winning Combination with New CoroMill Face and Shoulder Milling Cutters Face and Shoulder Milling Discover CoroMill milling solutions combining productivity and sustainability. Explore CoroMill's innovative milling cutters for excellence in demanding operations, focusing on the newest face and shoulder milling solutions. Achieve superior results with MS20, MS40, and MS60 cutters, combining productivity and environmental benefits when using advanced cutting technology. chevron_right

GC1230: A Serendipitous Success Story

Since the successful introduction of GC1230, our innovative Zertivo nano-multilayer PVD coating, we've witnessed unprecedented success across various material groups. Originally designed for ISO P alloy steel square shoulder milling applications, GC1230 has also excelled in ISO S materials, including Titanium alloys and Inconel billet materials. Unmatched performance across materials GC1230's performance in Titanium alloys (both clean and forged skin conditions) and Inconel billet materials is remarkable. This success is attributed to its improved edge line toughness, wear resistance, and coating adhesion. Unlike its predecessor, GC1130, GC1230 demonstrates exceptional versatility across multiple materials. Adaptability in modern processes For ISO S materials, GC1230 has proven effective in modern coolant-based processes, showcasing its ability to operate in both dry (preferable in steel) and wet conditions. This adaptability was not initially within our development scope, making this outcome a pleasant surprise for our global customer base, particularly in Aerospace, Defence, Pump & Valve, and Energy sectors. Supporting productivity and sustainability As industries strive for enhanced productivity and sustainability, GC1230 stands out as a solution aligned with these goals. Its durable nano-layered coating addresses key challenges in steel milling and other material groups by balancing heat resistance and durability. For manufacturers aiming to improve performance while meeting sustainability targets, GC1230 offers a practical and adaptable choice, supporting the industry's transition towards more efficient, sustainable practices on the shop floor. Conclusion GC1230's serendipitous success across various material groups highlights its versatility and reliability. As we continue to innovate, we are excited to see how GC1230 will further contribute to the productivity and sustainability goals of our diverse industry segments. Wayne Mason Global Product Application Manager Grades wayne.mason@sandvik.com GC1230: A Serendipitous Success Story Since the successful introduction of GC1230, our innovative Zertivo nano-multilayer PVD coating, we've witnessed unprecedented success across various material groups. Originally designed for ISO P alloy steel square shoulder milling applications, GC1230 has also excelled in ISO S materials, inclu... GC1230 Coating Success GC1230 excels in milling steel and exotic alloys with improved durability. GC1230 nano-multilayer coating excels in milling ISO P alloy steel and ISO S materials like Titanium and Inconel. The coating offers improved toughness, adaptability in dry and wet conditions, and supports sustainability goals. chevron_right