Let’s Talk: Tooling

Setting the standard

In an exclusive interview, Contributing Editor Steed Webzell speaks with Eugene Nugent, National Sales Manager at MAPAL UK, who is keen to shine the spotlight on an often-overlooked business area  

 First and foremost, most manufacturers with a machine shop will know MAPAL as a ‘specials’ company and technical solution provider. However, relatively few are aware that MAPAL also offers a substantial range of standard cutting tools. 

 “If someone wanted a 10mm diameter standard carbide drill, MAPAL wouldn’t automatically spring to mind as a potential source,” admits National Sales Manager Eugene Nugent. “And yet we have a full material-specific range of carbide drills, milling cutters and reamers on the shelf ready for delivery.” 

 Historically, MAPAL supplies bespoke tooling to key accounts like large automotive companies. The company remains the leading tooling supplier to many automotive OEMs and tier ones. However, it is the small-to-medium companies where MAPAL is seeking gains.  

 “We’ve gone from eight sales staff in 2022, to 14 today,” says Mr Nugent. “By adopting the traditional area sales manager strategy we now have people who can get familiar and build relationships with local small-to-medium manufacturers. It’s already starting to pay dividends. Everything is about awareness.”  

 For instance, how many know that MAPAL stocks HSS-E reamers in 10µm increments from 1 to 12mm in diameter? The company’s development of its standard range is intensive, supported by a huge R&D department in Germany.  

 “When developing a new tool, comprehensive testing takes place to ensure MAPAL’s reputation for high performance is upheld,” states Mr Nugent, who adds that workpiece materials have a huge influence on new tool development. “Variables such as edge preparation, flute profile and coating can change performance, which is why we’ve developed lots of material-specific tooling for milling and drilling. For instance, at EMO 2023 we’ll be launching a breakthrough in aluminium machining for aerospace applications where a high volume of material removal is necessary to meet the required machining strategies.” 

 Just 10 years ago, around 95% of business at MAPAL was automotive. However, in the past five years, the company’s presence in aerospace has grown to represent 25-30% of turnover. Further target sectors moving forward include fluid power and die and mould, where MAPAL has an extensive tooling portfolio to offer new sales channels. 

 Of course, automotive remains big business, particularly with the evolution of e-mobility and electric drive units. MAPAL has become the go-to tooling supplier for large stator housings, the bores of which carry very tight tolerances. Around 20% of all enquiries over the past six months relate to e-mobility, with further parts including transmission cases, clutch housings and battery trays.  

 Another notable side of MAPAL’s business is tool management. The company currently has 14 components in UK, including a clutch housing for an electric engine, operating on a cost-per-piece basis.  

“We supply the sharp edges and the manpower to set the tools, and get paid per part machined off the production line over the agreed contract period,” explains Mr Nugent. “The customer then enjoys the same cost per unit over the entire contract term. From MAPAL’s perspective, it’s in our interests to provide the customer with the best tools possible, as increased productivity adds to the success of such partnerships. Tool management is growing and today probably comprises around 10% of our business worldwide.”  

 Importantly, MAPAL works to global machining standards. All subsidiaries use the same machines, tooling and programs for product manufacturing. This strategy of continuity means customers always receive the same quality, for new and repaired tooling, regardless of geographical location.  

 As a final discussion point, Mr Nugent highlights the hot topic of sustainability, in particular MAPAL’s latest tool-holder technology.  

 “Many see shrink-fit as a low-cost way of holding a tool, but this technique is costly to both bottom-line profitability and the environment due to the requirement for so many heating/cooling cycles,” he says. “To overcome this issue we’ve come up with a hydraulic chuck range that offers the same profile as heat–shrink holders for complete swap-over compatibility. In situations where a large manufacturer is performing hundreds of tool changes a day, we estimate payback on our hydraulic solution within 12 months due to the significant energy savings.”  

 This development is indicative of MAPAL: real solutions with real customer benefits.