What is a CNC machining center?

A CNC (Computer Numerical Control) machining center is a highly automated, computer-controlled manufacturing tool used to perform various machining operations such as milling, drilling, and turning. These machines crank out complex components with minimal human oversight. With the ability to accommodate multiple tools and operate across multiple axes, CNC machining centers are all about adaptability and speed.

What is tool and die manufacturing?

Tool and die manufacturing provides the precision tools industries need to turn imagination into tangible results. With these tools, raw materials get a total makeover, emerging as sleek, high-quality products. Whether it's a precision aircraft part or a critical car component, skilled tool and die makers expertly operate advanced equipment, including grinders and lathes, to bring complex designs to life for industries that demand perfection. Crafting this workpiece from scratch calls for a rare blend of material know-how, sharp engineering instincts, and finesse on the machining floor.

How does plastic injection molding work?

To produce precise plastic parts, manufacturers turn to a time-tested process: injecting hot plastic into a custom-made mold that cools and solidifies the material. First, plastic pellets are heated to their melting point, transforming into a liquid state. The molten plastic is then injected with high pressure into the mold cavity. After cooling and solidifying, the mold is opened to eject the finished part. Mass-producing plastic components is a breeze with this process, thanks to its lightning-fast speed, pinpoint accuracy, and incredible shape-shifting abilities.

How do you become a tool and die maker?

A combination of book smarts, on-the-job training, and getting your hands dirty is typically what it takes to make it as a tool and die maker. Many start by completing a high school diploma or equivalent, followed by enrolling in a vocational school or technical college program specializing in machining, manufacturing, or engineering. To become a skilled tool and die maker, there's no substitute for the combo of in-class instruction and real-world training that apprenticeships offer. Want to supercharge your career? Top-notch CNC machining, CAD software, and metallurgy training can bring you up to speed - and make you a more attractive candidate.

How much does CNC machining cost?

Material selection, part design, machine runtime, labor expenses, and production quantities all play a role in determining the final cost of CNC machining. Simple parts with short machining times may cost as little as a few dollars per unit, while complex, highly precise components can range from tens to hundreds of dollars per piece. Custom prototypes typically cost more than mass-produced parts due to setup and programming expenses. For an accurate estimate, manufacturers usually request a CAD design and material specifications.

Tool and Die in the Automotive Industry Trends for 2025

Oct 20

Written By KIM RIEHLE

The automotive industry is in the midst of transformation. Driven by electrification, advanced materials, sustainability goals, and evolving consumer expectations, automotive manufacturing is pushing the envelope of what tool and die shops must deliver. In 2025, tooling providers will need to stay ahead of trends in design, materials, process automation, and integration. This post examines the key trends shaping tool and die in automotive for 2025 and how Barton Tool can help meet those demands.

Growth in Automotive Tooling and Castings

The global automotive tooling and castings market is forecast to grow significantly, with projections estimating a value of USD 98.5 billion in 2025, growing at a CAGR of around 6.2 percent into the early 2030s. Meanwhile, the specific die casting segment for automotive parts is expected to grow from about USD 16.4 billion in 2024 to more than USD 24.1 billion by 2030. These figures reflect the demand for lightweight, high-precision cast and stamped parts in modern vehicles.

Lightweighting and Material Innovation

One of the central drivers in automotive is lightweighting—the push to reduce vehicle weight for energy efficiency, emissions compliance, and performance. This means increased use of aluminum, magnesium, advanced high-strength steels (AHSS), and composite materials in structural and functional parts. Tooling must adapt to these materials, which behave differently in forming or machining. For example, die surfaces, coatings, lubrication strategies, and cooling design must evolve to handle thermal expansion, wear, and stress with these lighter substrates.

Electrification and EV-Specific Tooling

With electric vehicles (EVs) gaining market share, new tooling demands are emerging. EVs require battery enclosures, electric motor housings, cooling plates, connectors, and structural elements that differ from internal combustion engine (ICE) components. Tooling for battery frames, thermal management plates, and high-precision shielding must address high tolerances, thermal stability, and new material challenges. Die casting of battery housings or structural castings for EV bodies increases the demand for advanced casting dies.

Advanced Simulation, Digital Twin, and AI Integration

To accelerate design cycles and boost yield, automakers and tooling suppliers are increasingly using simulation, digital twin technology, and AI-aided inspection. Simulation enables die stress analysis, material flow prediction, and optimization before physical tooling is built. In 2025, trimming die inspection is likely to see more automation: one research effort automated trimming die inspection by integrating AI modules with CAD, reducing inspection time significantly. These technologies reduce risk, shorten development time, and improve first-pass success.

Additive Manufacturing for Tooling Components

Additive manufacturing (AM), or 3D printing, is playing a growing role in tooling—particularly for inserts, conformal cooling channels, and rapid prototyping dies. By printing complex internal cooling paths or lightweight support structures, tool builders can boost cooling efficiency, reduce cycle times, and extend tool life. Hybrid tools combining conventionally machined and additively manufactured sections are becoming more common in automotive tooling.

Automation, Robotics, and Smart Tooling

Automation in die handling, tool changeover, inspection, and measurement is rising. Robotics and gantry systems move heavy die sets, automate loading, or exchange inserts. Smart tooling that embeds sensors to monitor temperature, strain, force, or wear in real time is becoming more prevalent. This feedback enables predictive maintenance, more consistent quality, and reduced downtime.

Lean, Industry 4.0, and Toward Industry 5.0

Automotive suppliers are increasingly adopting lean manufacturing and integrating Industry 4.0 principles—data connectivity, IoT monitoring, and process analytics. Some researchers now propose moving toward Industry 5.0, which emphasizes human-centric approaches integrated with digital systems. In the tooling context, this may mean augmented reality (AR) assistance for die setup, operator guidance, and better human-machine collaboration in complex tool operations.

Challenges and Risks in 2025

Rising material and energy costs: Tooling shops may see higher costs for tool steels, coatings, and energy consumption.
Supply chain disruptions: Delays in raw materials, rare alloys, or electronic components may slow tooling delivery.
Shorter vehicle cycles: Automakers want faster model turnover, which pressures tooling lead times.
Regulatory and environmental constraints: Tooling processes must align with sustainability, emissions, and waste rules.
Economic volatility: If vehicle sales soften, demand for new tooling may stall, putting pressure on tool shops to diversify or operate lean.

What Barton Tool Offers for 2025 Challenges

At Barton Tool, we are primed to meet the evolving needs of automotive clients. Our expertise includes:

Designing dies and tooling optimized for lightweight materials, composite components, and EV systems
Incorporating simulation and digital twin workflows early in tool development
Offering hybrid tooling solutions that leverage additive manufacturing and traditional methods
Embedding sensor readiness and monitoring in tool design for real-time diagnostics
Supporting lean and connected manufacturing to align with Industry 4.0/5.0 practices

Conclusion

Tool and die in the automotive industry is advancing rapidly in response to electrification, materials innovation, digital integration, and automation. The toolmakers who succeed in 2025 will be those who blend design agility, smart tooling, and efficient processes. If you’re planning new automotive tooling projects or want to discuss how Barton Tool can help you stay ahead of these trends, contact us today!

KIM RIEHLE