Tool & die makers work to exceptionally fine tolerances. Whether you’re shaping mould cavities, machining dies, preparing inserts or polishing critical shut-offs, every stage depends on using tools that cut cleanly, polish predictably and maintain accuracy throughout the job.
This guide breaks down the essential stages of tool & die work and shows which small precision tools are used for each step — drilling, shaping, detailing, stoning, polishing and finishing — with links to Eternal Tools products where relevant.
1. Drilling, Slotting & Opening Up Cavities
The first stage in most tool & die projects is opening up cavities, machining slots or producing small holes for pins, inserts or fasteners. This is where accuracy at the start prevents problems later on.
Diamond Drill Bits
Diamond Drill Bits excel on tough, brittle or hardened materials. They maintain position where standard drills may slip or chip, making them ideal for:
- Drilling ejector pin holes and cooling channels
- Starting holes in hardened tool steels
- Working on carbide inserts or ceramics
End Mills, Slot Drills, Milling Cutters & Routers
End mills and slot drills remove bulk material and establish primary geometry. They shape pockets, flats and forms that later require hand refinement. A good milling finish reduces time spent with burrs and stones later.
Micro Taps
Micro taps allow the creation of extremely fine threads in jigs, fixtures and small components. Their precision is ideal for delicate adjustments and miniature fasteners common in fine toolmaking work.
2. Shaping, Blending & Detailed Metal Removal
After milling, tool & die makers refine forms, add radii and remove machining marks. This is where rotary burrs and countersink tools come into play.
Carbide Rotary Burrs
Carbide rotary burrs are ideal for shaping and heavy stock removal on hardened steels. Common uses include:
- Blending internal corners
- Removing machining marks
- Forming smooth radii inside mould cavities
Diamond Burrs
Diamond burrs shine when working on very hard or brittle materials such as tungsten carbide, hardened steel and wear-resistant alloys. They also allow extremely controlled material removal on fine details.
Diamond Coated Countersink Bits & Carbide Countersink Burrs
Countersink tools help break sharp edges, chamfer holes and remove burrs left from milling or drilling. Diamond-coated versions are perfect for hard or wear-resistant materials, while carbide versions give crisp, chatter-free chamfers in steel.
Scribers
Scribers assist with layout marking, checking alignment, and mapping finishing sequences. Tool & die makers use them to mark datum lines, centres and trim edges prior to machining or finishing.
3. Surface Refinement: Stoning, Filing & Controlled Handwork
This is where precision really comes from. Hand refinement ensures edges meet cleanly, radii are consistent and shut-offs seal properly.
Diamond Files & Sharpeners
Diamond files cut hardened steels smoothly without tearing. They’re ideal for tidying internal corners, refining geometry and removing small burrs.
Files and burnishers offer finer control for smoothing contours, edges and forms. Burnishers compact and brighten the surface, ideal for pivots, pins and tight working surfaces. Abrasive stones – from Arkansas to composite stones – allow precise control of surfaces that need straightening, flattening or transitioning between machined and manual work. They’re indispensable for: Stones & Sharpeners include grinding wheels, bench stones, slip stones and specialist sharpening stones used both for hand-finishing workpieces and for maintaining toolroom cutters, form tools and punches. Dressing tools keep grinding wheels and abrasive tools cutting properly by exposing fresh abrasive and restoring the correct profile. This ensures better finishes and reduces heat generation. Once the surface is shaped and stoned, rotary polishers help remove fine scratches and prepare for the final polishing stages. Rubber polishers, silicone polishers and mounted abrasives clean up surfaces left by stoning and burr work. They’re excellent for: Abrasive papers, sheets and pads allow sanding in tight spaces by wrapping around dowels, files or shaped tools. They are ideal for smoothing internal features and refining contours before moving on to felt polishing. Felt tools are essential for controlled polishing in small areas. Used with diamond paste, they create uniform finishes and crisp transitions. Brushes and buffs are often used at the final stage to clean residues from radii, corners and textured surfaces, leaving a clean, bright finish. Different grades of polishing compound control how quickly you cut and how fine a finish you achieve. Diamond compound is especially effective on hardened steels and carbide, delivering reliable, repeatable results. Accuracy depends on both the tool and how securely the workpiece is held or measured. Small vices and movement holders secure inserts, pins and small plates during stoning, polishing or drilling. Precise work is impossible without reliable workholding. Mandrels and adaptors keep mounted points running true in a rotary tool. Poor alignment leads to vibration, heat and uneven finishing. From calipers to depth gauges, accurate measurement guides every stage of tool & die work and ensures the final component fits, seals and operates as intended. A well-rounded tool & die maker’s kit usually includes: This workflow — from machining to shaping, stoning and polishing — ensures consistent, high-quality results across dies, moulds, punches and precision inserts. Whether you’re finishing an injection mould cavity, repairing a stamping die or creating a precision fixture, the right tools make every stage faster, smoother and more accurate. Browse the full collection here:
Steel Files & Burnishers
Abrasive Stones
Stones & Sharpeners
Dressing & Truing Tools
4. Rotary Polishing & Pre-Finish Smoothing
Rotary Tool & Pendant Drill Polishers
Abrasive Papers, Pads & Cloths
Felt Polishing Bobs, Points & Wheels
Polishing Brushes & Buffs
Polishing Pastes, Powders & Compounds
5. Assembly, Workholding & Measurement
Vices & Movement Holders
Mandrels, Arbors, Adaptors & Collets
Measuring Devices
6. Putting Together a Complete Toolroom Kit
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