How to Save Money in Mould and Die Manufacturing / development?

In mould and die manufacturing, saving money is rarely about choosing the lowest-cost process at the start. The real savings come from avoiding rework, rejected parts, extended machining time, poor cooling performance, and delivery delays later.

One area that has a major impact on both cost and tool performance is deep-hole drilling—especially for cooling channels, ejector-pin holes, guide holes, hydraulic passages, and other long, accurate bores.

Gun drilling and deep-hole drilling can help mould and die manufacturers reduce total production cost while improving quality, cycle time, and tool life.

1. Prevent expensive rework from inaccurate holes

A small deviation in a deep hole can create a large problem. Off-centre, tapered, rough, or misaligned holes may cause:

- Poor cooling-water flow

- Uneven temperature distribution

- Leakage or fitting problems

- Difficulty during assembly

- Scrapped inserts or plates

- Additional EDM, boring, or correction work

Deep-hole drilling is designed to achieve straight, accurate holes with a controlled finish and consistency. Getting the hole right in the first operation helps eliminate the hidden cost of repeated machining and manual correction.

2. Improve cooling efficiency and reduce moulding cycle time

Cooling-channel design directly affects moulding productivity. If channels are positioned accurately and drilled close to the mould cavity where appropriate, heat can be removed more efficiently.

Better cooling can lead to:

- Shorter moulding cycles

- More consistent part quality

- Less warpage and shrinkage variation

- Higher output from the same machine

- Lower energy use per component

Even a modest reduction in cycle time can create significant savings over a high-volume production run. Accurate gun drilling supports the cooling layout needed to achieve that improvement.

3. Reduce machining time on long holes

Conventional drilling can be slow and unreliable for long length-to-diameter ratios. It may require multiple setups, peck drilling, frequent tool withdrawal, and corrective operations.

A dedicated gun-drilling process is better suited for deep, small-to-medium diameter holes. It can reduce setup complexity and machine time while improving repeatability.

This is especially valuable for mould plates, core inserts, die blocks, shafts, and precision tooling where deep holes are a regular requirement.

4. Avoid unnecessary tool and material wastage

High-value mould steel and die steel should not be exposed to avoidable risk. A failed deep-hole operation late in the manufacturing cycle can mean loss of a costly component as well as the machining already invested in it.

Using the right drilling process early helps protect material value by reducing the risk of:

- Broken drills inside the job

- Hole deviation

- Surface damage

- Incomplete coolant passages

- Incorrect hole location

- Scrap after expensive prior machining

The cost of specialist drilling is often far lower than the cost of losing one finished or near-finished mould component.

5. Simplify assembly and maintenance

Well-executed deep holes make assembly smoother. Ejector holes, guide holes, cooling passages, and lubrication lines fit together more predictably when their size, straightness, and surface finish are controlled.

This can reduce fitting time during mould assembly and make future maintenance easier. Clean, accurate passages also support reliable coolant flow and reduce the chance of unexpected production interruptions.

6. Outsource specialist work instead of investing in underused capacity

Not every mould and die shop needs to own a dedicated deep-hole drilling machine. Capital investment, operator training, tooling inventory, maintenance, and floor space can be difficult to justify when deep-hole work is occasional or variable.

Outsourcing gun drilling to a specialist lets manufacturers access the right capability when they need it, without carrying the full cost of owning and operating the equipment.

It is a practical way to keep fixed costs lower while maintaining quality on demanding jobs.

7. Plan drilling early in the mould design stage

The greatest savings come when deep-hole drilling is considered before manufacturing begins.

During design and process planning, review:

- Hole diameter and depth

- Length-to-diameter ratio

- Hole location and access

- Required straightness and surface finish

- Cooling-channel layout

- Material grade and hardness

- Required plugs, fittings, and cross-holes

Early planning helps avoid designs that are difficult or costly to machine. It also allows the drilling process to be coordinated with milling, EDM, heat treatment, and finishing operations.

Choose precision where it matters

Mould and die manufacturers face constant pressure to deliver faster, maintain accuracy, and control cost. Precision deep-hole drilling supports all three goals by reducing rework, improving cooling performance, protecting expensive materials, and making production more predictable.

For critical deep-hole requirements in mould bases, inserts, die blocks, fixtures, and precision components, Riseom Group provides gun drilling and deep-hole drilling services focused on accuracy, repeatability, and dependable turnaround.

A well-drilled hole is not just a machining feature—it is an investment in lower manufacturing cost and better mould performance.