In addition to modular endmilling systems specifically designed for mold-making and other copymilling applications, general indexable-insert endmilling systems are available that include components for high-speed/high-feed finishing of molds and dies.

Using one such system, ballnose endmills in diameters from 0.250 inch to 0.750 inch can easily be assembled by screwing a single precision-ground indexable carbide insert (with a choice of two or three effective cutting edges) into a reusable steel or heavy-metal tool shank. The insert clamping mechanism ensures rigid and secure insert retention.

Ballnose endmills created from the modular endmilling system offer performance and productivity in high-speed finishing of molds and dies. For example, using a balanced high-speed-steel shank, these tools can be safely run at cutting speeds up to 12,000 sfpm.
The modular ballnose endmills also are very accurate. Precision ballnose inserts, for instance, achieve dimensional tolerances ranging from +0.0002 inch to 0.0006 inch – easily matching results obtained with any solid-carbide cutters.

In addition to their high-performance capabilities, modular ballnose endmills can satisfy a broad range of particular application requirements and operating preferences from roughing to semi-finishing and finishing.

The modular endmilling system also provides a wide selection of shanks, ranging from stubby cylindrical styles to long styles for added reach. At the very high machining speeds obtained with finishing ballnose endmills, the shorter, more stable shank design provides added performance reliability. If a longer reach is needed, heavy-metal shanks are available in lengths to meet most reach requirements, while also providing the stability needed for good machining performance.