August 2025 Volume 7

EQUIPMENT & TECHNOLOGY

Photo Courtesy of Gemini Group.

Photo courtesy of EST Tool.

Forging Tooling: Smarter, Faster, and More Durable Customer Demands Drive Innovation Tooling suppliers report increased pressure to deliver longer-lasting, more precise tools at faster turnaround times. Stephanie Speck of Gemini Group emphasized tooling design as key to performance, while Beau Parker of EST Tool pointed out the rise in tighter tolerances, high temperature durability, and demand for engineering support upfront. When asked about how customar demand has changed recently, Speck stated “We’ve seen more customers outsource tooling design rather than keeping it inhouse due to lack of resources.” “Customers now expect tooling to hold up longer and be ready faster,” Parker said. “This includes working with more complex alloys like Inconel and titanium.” Quick-Change Tooling and Digitalization Quick-change die systems and replaceable inserts are gaining popularity for their ability to reduce downtime and adapt to short runs. “Die design and using insert or quick change tooling will bring cost down and production up,” according to Speck. Parker’s team at EST Tool also supports customers through surface treatments, optimized tool steel selection, and digital planning. EST Tool’s integration of the ZOLLER presetter and Tool Management System has allowed them to improve setup speed, tool accuracy, and quality traceability. “We’ve cut down setup time and increased repeatability across jobs,” said Parker.

Addressing Lead Times and Labor Gaps To meet demand, Parker shared that EST Tool is investing in new ERP software, advanced scheduling, and reserving capacity for key customers. “Expedited requests have become the norm in 2025,” he said. In response to the industry-wide talent gap, the company is documenting processes and leaning into digital tools to preserve expertise for the next generation. Supporting Performance with Surface Treatments Advanced tool steels such as Dievar and ESR-grade H13 are now more common in forging. EST Tool also applies vacuum heat treatments, nitriding, PVD coatings (TiN, AlCrN), and even cryogenics to reduce wear and extend tool life—particularly in high Both Parker and Speck highlighted the importance of working closely with customers. EST Tool recently supported a new client by designing custom trimmer dies that performed successfully from the first run. “We tailored the design to their part geometry, press specs, and production flow—no rework needed,” Parker said. Looking Ahead: The Next Five Years Material and tooling experts agree that the future of forging will be defined by: • Smarter Tooling: Automation-ready designs, simulation-driven setups, and modular systems • Strategic Sourcing: Multi-sourcing strategies and domestic supplier relationships • Digital Integration: Simulation, CAD/CAM linkages, and inventory-driven planning • Workforce Transition: Tools and processes that support knowledge transfer and ease training Precision, Planning, and Partnerships Whether dealing with cutting-edge alloys or complex die geometries, the future of forging relies on close collaboration and technical transparency. “More collaboration across the supply chain—from material properties to downstream tooling—can dramatically improve outcomes,” said Oettli. “It’s not just about quoting specs. It’s about sharing knowledge early in the process.” McIntosh agreed: “Challenge single-sourcing mandates and support options that improve flexibility.” Thank you to Beau Parker (EST Tool); Matt Oettli (Metallus); Graham McIntosh (Universal Stainless); and Stephanie Speck (Gemini Group) for their contributions to this article. volume or abrasive applications. Collaboration Leads to Success

FIA MAGAZINE | AUGUST 2025 15