Cavalier Tool is constantly pushing the boundaries of innovation to stay ahead in the mold making industry. Recently, our President, Brian Bendig, along with Plant Manager Larry Caron and Maintenance Manager Rob Wilson, embarked on a strategic trip to Europe.

Their mission? To tour the world’s leading machine suppliers in search of a heavy-duty roughing machine that can further optimize our processes.

The Need for a Heavy-Duty Solution

In mold making, roughing is an essential step – a demanding and high-torque operation that shapes raw materials into the initial form of a mold. As our production volume continues to grow, Bendig and the rest of the leadership team have marked roughing operations as a key channel for growth.

“Roughing is the first operation in the mold making process. It’s a gritty and tough operation. With the volume we’re at, we need to rough better than we ever have,” Bendig explained.

Our current roughing process primarily relies on boring mills. While effective, these machines are slower and not specifically designed for the type of heavy-duty roughing processes that we envision. “Boring mills lend themselves to our operations because they have high torque. However, there are better solutions out there that can enhance our speed and efficiency,” Bendig added.

The Search for Innovation

During their tour, the Cavalier team focused on finding a large machine capable of handling roughing at a higher speed, with greater automation and flexibility. “We don’t need ten machines, but we need one really good rougher,” said Bendig. The team explored various configurations, ultimately narrowing their focus to horizontal machines.

A horizontal configuration offers significant advantages for chip evacuation. “When you mill in a vertical position, chips accumulate and can lead to recutting, which damages tools and the workpiece. A heavy-duty roughing machine with a horizontal configuration allows chips to fall away naturally, improving efficiency and quality,” Bendig explained.

Additionally, the team assessed machines equipped with rotating tables and head exchangers. These features allow for multiple operations with various heads, including large roughing heads, extension heads, and orthogonal heads that provide access to difficult angles. This versatility is essential for maximizing efficiency and minimizing downtime.

Improving the Process

Cavalier Tool plans to integrate the new machine into Plant 2, streamlining operations across both facilities. “We are removing two machines and replacing them with this high-capacity rougher,” Bendig said. “All blocks will be prepped and roughed at Plant 2, then transferred to Plant 1 for finishing. This setup will reduce trucking costs and increase overall efficiency.”

Automation plays a key role in the decision-making process. The new machine will feature unattended machining capabilities, reducing the need for manual intervention. “Speed is critical for us, and unattended machining allows for greater productivity during off-hours,” Bendig noted. With the potential to cut roughing times in half, this machine will significantly enhance our production timeline.

Delivering Value to Customers

For Cavalier Tool, investing in a heavy-duty roughing machine isn’t just about enhancing internal operations – it’s about accelerating delivery while maintaining the high quality our customers expect.

“Our goal is to rough faster and better. This means shorter lead times and increased value for our customers,” Bendig emphasized.

With this significant surge in our roughing capabilities, Cavalier Tool will continue to push the mold making industry, providing reliable, high-performance solutions that meet the evolving needs of our clients.

Stay tuned for updates as The Cavalier Experience continues to evolve.