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Threading

 Introduction to Threading

Threading is used to create high-accuracy internal and external threads in a range of materials. Whether for aerospace fasteners, automotive components, or medical implants, the right threading tool selection is critical for dimensional accuracy, tool longevity, and process efficiency.

Exactaform’s PCD thread mills are engineered for high-performance threading in abrasive materials, significantly outlasting carbide and coated alternatives. Offering superior wear resistance and precision, our PCD thread mills provide consistent thread form accuracy, reducing rework and tool replacements. With off-the-shelf options and custom sizes available, Exactaform delivers the best solution for high-precision threading applications.

Types of Threading Tools 

Exactaform provides a range of PCD thread mills, designed to increase productivity, improve tool life, and enhance thread quality.

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PCD Thread Mills

The ultimate solution for precision thread milling, delivering 10× tool life compared to carbide tools, ensuring thread form integrity without tooth breakdown or wear.

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Off-the-Shelf Thread Mills

Available for immediate delivery, covering standard sizes M4 – M12, with optimised LOC, reach, and overall length (OAL) to meet diverse machining needs.

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Custom Thread Mills

Engineered for bespoke applications, with thread sizes available from M3 upwards to suit aerospace, motorsport, and medical machining requirements.

Materials for Surface Machining Applications

PCD Surface Machining

Best for non-ferrous materials where surface quality and tool longevity are critical.

Aluminium

High-speed milling and precision finishing for wing skins, fuselage panels, and automotive body components, where consistent surface characteristics and reduced average roughness (Ra) are essential.

CFRP (Carbon Fibre Reinforced Polymer) CFRP

Delamination-free trimming and finishing of aerospace structures and motorsport chassis, ensuring accurate surface profile with no need for post-processing.

Other Composites

Precision machining of lightweight structural components in aviation, defence, and high-performance sectors, delivering both dimensional accuracy and refined finishes across varied composite layups.

Carbide Surface Machining

Best for high-strength metals where surface roughness, strength, and tool control are key.

Titanium

Ideal for load-bearing aerospace structures and high-performance automotive parts, maintaining low Roughness Average (Ra) values and excellent fatigue resistance.

Inconel & Nimonic Alloys

High-temperature milling for turbine components, engine parts, and exhaust systems, where surface finish must align with critical aerospace specifications.

Steel & Hardened Steel

Applied in automotive drivetrain components, landing gear, and structural aerospace parts, including stainless steels. Supports both CNC machining and chemical milling processes to meet tight surface finish tolerances.

Exactaform’s tooling is compatible with both contact and non-contact surface inspection methods, enabling manufacturers to meet strict surface quality standards, reduce production costs, and minimise variation in surface finish across complex part geometries.

Bespoke Threading Design

 Alongside our off-the-shelf range, Exactaform offers bespoke PCD thread mills, tailored to industry, material, and component-specific machining challenges, ensuring superior tool life, precision thread cutting, and process efficiency for demanding applications.

Cutting Strategies & Cutting Data for Surface machining 

Achieving the best surface finish and maximising tool life requires cutting strategies tailored to tool type, material properties, and machining conditions. Exactaform’s application engineers work closely with manufacturers to optimise every stage of the process, ensuring consistency and quality.

We help determine:

  • The ideal tool path and feed rate for each tool type, reducing tool marks and improving surface uniformity.
  • Optimised cutting speeds that minimise heat generation and tool wear, while aligning with desired surface roughness chart values.
  • Depth-of-cut adjustments based on part geometry and material response, ensuring consistent surface finishes across complex contours.

Whether you’re targeting a smooth finish, a defined Baseline finish, or specific Roughness Average (Ra) values for optical components, our team delivers data-driven support.

With both on-site consultation and off-site process optimisation, Exactaform helps engineers implement tool-specific strategies that reduce cycle times, enhance productivity, and maintain surface integrity - no matter the finish level or complexity of the material.

Why Choose Exactaform for Surface machining

With over 45 years of expertise in cutting tools, Exactaform offers bespoke surface machining solutions with industry-leading tool life, precision, and repeatability, supported by application-driven engineering and cutting strategy expertise.

FAQ’s