Tool and Die Makers

• Most tool and die makers train for 4 or 5 years in apprenticeships or postsecondary programs; employers typically recommend apprenticeship training.
• Employment is projected to decline because of strong foreign competition and advancements in automation.
• Excellent job opportunities are expected; employers in certain parts of the country report difficulty attracting well-trained applicants.

Tool and die makers are among the most highly skilled workers in manufacturing. These workers produce tools, dies, and special guiding and holding devices that enable machines to manufacture a variety of products we use daily—from clothing and furniture to heavy equipment and parts for aircraft.

Toolmakers craft precision tools and machines that are used to cut, shape, and form metal and other materials. They also produce jigs and fixtures (devices that hold metal while it is bored, stamped, or drilled) and gauges and other measuring devices. Die makers construct metal forms (dies) that are used to shape metal in stamping and forging operations. They also make metal molds for diecasting and for molding plastics, ceramics, and composite materials. Some tool and die makers craft prototypes of parts, and then, working with engineers and designers, determine how best to manufacture the part. In addition to developing, designing, and producing new tools and dies, these workers also may repair worn or damaged tools, dies, gauges, jigs, and fixtures.

To perform these functions, tool and die makers employ many types of machine tools and precision measuring instruments. They also must be familiar with the machining properties, such as hardness and heat tolerance, of a wide variety of common metals, alloys, plastics, ceramics, and other composite materials. As a result, tool and die makers are knowledgeable in machining operations, mathematics, and blueprint reading. In fact, tool and die makers often are considered highly specialized machinists. The main difference between tool and die makers and machinists is that machinists normally make a single part during the production process, while tool and die makers make parts and assemble and adjust machines used in the production process. (See the statement on machinists elsewhere in the Handbook.)

Traditionally, tool and die makers, working from blueprints, first must plan the sequence of operations necessary to manufacture the tool or die. Next, they measure and mark the pieces of metal that will be cut to form parts of the final product. At this point, tool and die makers cut, drill, or bore the part as required, checking to ensure that the final product meets specifications. Finally, these workers assemble the parts and perform finishing jobs such as filing, grinding, and polishing surfaces. While manual machining has declined, companies still employ it for some simple and low-quantity parts.

Most tool and die makers today use computer-aided design (CAD) to develop products and parts. Specifications entered into computer programs can be used to electronically develop blueprints for the required tools and dies. Numerical tool and process control programmers use computer-aided design or computer-aided manufacturing (CAD/CAM) programs to convert electronic drawings into CAM-based computer programs that contain instructions for a sequence of cutting tool operations. (See the statement on computer control programmers and operators elsewhere in the Handbook.) Once these programs are developed, computer numerically controlled (CNC) machines follow the set of instructions contained in the program to produce the part. Computer-controlled machine tool operators or machinists normally operate CNC machines; however, tool and die makers are trained in both operating CNC machines and writing CNC programs, and they may perform either task. CNC programs are stored electronically for future use, saving time and increasing worker productivity.

After machining the parts, tool and die makers carefully check the accuracy of the parts using many tools, including coordinate measuring machines (CMM), which use software and sensor arms to compare the dimensions of the part to electronic blueprints. Next, they assemble the different parts into a functioning machine. They file, grind, shim, and adjust the different parts to properly fit them together. Finally, the tool and die makers set up a test run using the tools or dies they have made to make sure that the manufactured parts meet specifications. If problems occur, they compensate by adjusting the tools or dies.

Tool and die makers usually work in toolrooms. These areas are quieter than the production floor because there are fewer machines in use at one time. They also are generally kept clean and cool to minimize heat-related expansion of metal workpieces and to accommodate the growing number of computer-operated machines. To minimize the exposure of workers to moving parts, machines have guards and shields. Most computer-controlled machines are totally enclosed, minimizing the exposure of workers to noise, dust, and the lubricants used to cool workpieces during machining. Tool and die makers also must follow safety rules and wear protective equipment, such as safety glasses to shield against bits of flying metal, earplugs to protect against noise, and gloves and masks to reduce exposure to hazardous lubricants and cleaners. These workers also need stamina because they often spend much of the day on their feet and may do moderately heavy lifting.

Companies employing tool and die makers have traditionally operated only one shift per day. Overtime and weekend work are common, especially during peak production periods.

Most tool and die makers learn their trade through 4 or 5 years of education and training in formal apprenticeships or postsecondary programs. Apprenticeship programs include a mix of classroom instruction and on-the-job-training. According to most employers these apprenticeship programs are the best way to learn all aspects of tool and die making. A number of tool and die makers receive most of their formal classroom training from community and technical colleges, often in conjunction with an apprenticeship program.

Traditional apprenticeship programs allowed workers to advance by completing a set number of hours of on-the-job-training and successfully completing specific courses. The National Institute of Metalworking Skills (NIMS) is developing new standards that would replace the required number of hours with competency- based tests. Whether competency tests will change the length of the traditional training process will probably depend upon the apprentice’s prior experience, dedication, and natural ability. However, the required training courses for a journeyman tool and die maker will continue to take 4-5 years to complete.

Even after completing the apprenticeship, tool and die makers still need years of experience to become highly skilled. Most specialize in making certain types of tools, molds, or dies.

Tool and die maker trainees learn to operate milling machines, lathes, grinders, wire electrical discharge machines, and other machine tools. They also learn to use handtools for fitting and assembling gauges, and other mechanical and metal-forming equipment. In addition, they study metalworking processes, such as heat treating and plating. Classroom training usually consists of tool designing, tool programming, blueprint reading, and, if needed, mathematics courses, including algebra, geometry, trigonometry, and basic statistics. Tool and die makers increasingly must have good computer skills to work with CAD/CAM technology, CNC machine tools, and computerized measuring machines.

Workers who become tool and die makers without completing formal apprenticeships generally acquire their skills through a combination of informal on-the-job training and classroom instruction at a vocational school or community college. They often begin as machine operators and gradually take on more difficult assignments. Many machinists become tool and die makers.

Because tools and dies must meet strict specifications—precision to one ten-thousandth of an inch is common—the work of tool and die makers requires skill with precision measuring devices and a high degree of patience and attention to detail. Good eyesight is essential. Persons entering this occupation also should be mechanically inclined, able to work and solve problems independently, have strong mathematical skills, and be capable of doing work that requires concentration and physical effort.

Employers generally look for someone with a strong educational background as an indication that the person can more easily adapt to change, which is a constant in this occupation. As automation continues to change the way tools and dies are made, workers regularly need to update their skills in order to learn how to operate new equipment. Also, as materials such as alloys, ceramics, polymers, and plastics are increasingly used, tool and die makers need to learn new machining techniques to deal with the new materials.

There are several ways for skilled workers to advance. Some move into supervisory and administrative positions in their firms or they may start their own shop. Others may take computer courses and become computer-controlled machine tool programmers. With a college degree, a tool and die maker can go into engineering or tool design.

Tool and die makers held about 103,000 jobs in 2004. Most worked in industries that manufacture metalworking machinery, transportation equipment (such as motor vehicle parts and aerospace products), and fabricated metal products, as well as plastics product manufacturing. Although they are found throughout the country, jobs are most plentiful in the Midwest, Northeast, and West, where many of the metalworking industries are located

Despite declining employment, excellent job opportunities are expected. Employers in certain parts of the country report difficulty attracting qualified applicants. The number of workers receiving training in this occupation is expected to continue to be fewer than the number of openings created each year by tool and die makers who retire or transfer to other occupations. A major factor limiting the number of people entering the occupation is that many young people who have the educational and personal qualifications necessary to learn tool and die making may prefer to attend college or may not wish to enter production occupations.

Employment of tool and die makers is projected to decline over the 2004-14 period because of strong foreign competition and advancements in automation, including CNC machine tools and computer-aided design, that should improve worker productivity. On the other hand, tool and die makers play a key role in building and maintaining advanced automated manufacturing equipment. As firms invest in new equipment, modify production techniques, and implement product design changes more rapidly, they will continue to rely heavily on skilled tool and die makers for retooling.

Median hourly earnings of tool and die makers were $20.55 in May 2004. The middle 50 percent earned between $16.70 and $25.93. The lowest 10 percent had earnings of less than $13.57, while the top 10 percent earned more than $31.19. Median hourly earnings in the manufacturing industries employing the largest numbers of tool and die makers in May 2004 are:

Apprentice’s pay is tied to their skill level. As they gain more skills and reach specific levels of performance and experience, their pay increases.

The occupations most closely related to the work of tool and die makers are other machining occupations. These include machinists; computer control programmers and operators; and machine setters, operators, and tenders—metal and plastic. Another occupation that requires precision and skill in working with metal is welding, soldering, and brazing workers.

Like tool and die makers, assemblers and fabricators assemble complex machinery. When measuring parts, tool and die makers use some of the same tools and equipment that inspectors, testers, sorters, samplers, and weighers use in their jobs.

For career information and to have inquiries on training and employment referred to member companies, contact:

• Precision Machine Products Association, 6700 West Snowville Rd., Brecksville, OH 44141-3292. Internet: http://www.pmpa.org/

For lists of schools and employers with tool and die apprenticeship and training programs, contact:

• National Tooling and Machining Association, 9300 Livingston Rd., Ft. Washington, MD 20744. Internet: http://www.ntma.org/

For information on careers, education and training, earnings, and apprenticeship opportunities in metalworking, contact:

• Precision Metalforming Association Educational Foundation, 6363 Oak Tree Blvd., Independence, OH 44131-2500.

• Source: Bureau of Labor Statistics, U.S. Department of Labor, Occupational Outlook Handbook, 2006-07 Edition