Exactaform Logo

Milling

Introduction to Milling

Milling is a high-precision machining process used to produce complex geometries, tight tolerances, and high-quality surface finishes across a wide range of industries. Whether manufacturing aerospace components, automotive parts, or precision engineering assemblies, selecting the right milling tool is essential for optimising performance, efficiency, and tool longevity.

Exactaform offers an extensive portfolio of milling solutions - including PCD, carbide, and diamond-coated tools - engineered for high-speed cutting, abundant material removal, and fine surface finishing. Designed for both CNC machining and manual operations, our milling machine tools feature optimised geometries and advanced coatings that reduce cycle times, extend tool life, and boost overall machining productivity.

Types of Mills

Exactaform offers a wide range of milling tools engineered for precision machining, high-speed cutting, and extended tool life across multiple industries. Additional options include fly cutters, slot milling cutters, and plunge mills - all fully customisable in geometry, flute design, coating, and material to suit specific applications.

Exactaform Icon

End Mills

Available in finishing, roughing, chip breaker, and ripping styles with fine pitch and knuckle form geometries to enhance metal removal rates, chip flow, and tool control.

Exactaform Icon

Face Mills

Designed for high-speed, high-precision surface machining, delivering efficient and consistent finishes.

Exactaform Icon

Exacta-Set PCD Milling Cutters

A cartridge-style PCD system with adjustable axial settings and chip deflection for increased stability and superior surface quality.

Exactaform Icon

Ball Nose Mills

Ideal for contouring and 3D profiling, particularly in 5-axis milling machines.

Exactaform Icon

Thread Mills

Provide accurate thread forms in tough materials.

Materials Our Mills Can Be Used For

Exactaform’s milling tools are engineered for high-precision machining in aerospace, automotive, and advanced engineering environments, delivering outstanding accuracy, productivity, and extended tool life across a wide range of materials.

Each tool is designed to maximise performance based on material properties, machining strategy, and surface finish targets.

PCD Mills

Best for non-ferrous and brittle materials:

Aluminium

Enables high-speed milling with excellent surface finish and dimensional control, ideal for Fly cutter setups and precision profile milling.

CFRP & Composites

Designed to minimise delamination and fibre pull-out, ensuring smooth edges and high component integrity on CNC routers and automated milling machines.

Carbide Mills

Designed for high-strength and heat-resistant metals:

Titanium & Nickel Alloys

Optimised for aerospace applications requiring strong chip control, especially in vertical and 5-axis milling machines.

Inconel & Nimonic Alloys

Excellent for high-temperature milling in turbine and engine parts.

Steel & Hardened Steel

Suitable for structural machining and iron milling, offering long tool life and consistent finish.

Diamond-Coated Mills (DC Mills)

Ideal for abrasive materials

Graphite & Carbon Composites

Deliver reduced tool wear and high machining consistency in high-volume CNC or universal milling operations.

Bespoke Mill Design

We specialise in bespoke milling solutions, designing custom tools tailored to specific industries, materials, and component geometries. Our engineers work closely with manufacturers to ensure optimal performance and machining accuracy.

Alongside our bespoke milling tools, we also offer a selection of proven standard tools:

  • Carbide End Mill Range – Designed for machining titanium, aluminium, and steel with excellent performance and extended tool life.
  • Exacta-Set PCD Milling System – A cartridge-style rotary cutter system engineered for precision, durability, and productivity in high-volume CNC and manual applications, including turret mills and vertical machining centres.

Whether solving a complex machining challenge or selecting a reliable standard tool, Exactaform provides the right milling technology for your application.

Cutting Strategies & Cutting Data for Mills

Optimising milling performance depends on applying the correct cutting strategies and data. Key parameters such as spindle speed, feed rate, radial depth of cut, and chip load all directly influence tool life, surface finish, and machining efficiency.

Exactaform’s application engineers work closely with manufacturers to fine-tune milling strategies across a variety of operations - from roughing and slot milling to contour and profile finishing. We help determine the optimal:

  • Tool path and feed direction for maximum material removal and reduced tool wear
  • Spindle speeds and chip loads suited to carbide, PCD, or diamond-coated mills

Depth-of-cut and cutter engagement for consistent accuracy and surface integrity

Whether you’re using face mills on vertical machining centres or end mills in high-speed CNC operations, Exactaform provides both on-site support and expert recommendations to maximise your tool performance and extend tool life across all milling applications.

Why Choose Exactaform for Mills

With over 45 years of experience, Exactaform delivers complete solutions for the production process, offering tools compatible with 5-axis machines, rotary tables, and milling spindles, optimised for precision and productivity.

FAQ’s