TOOL AND DIE MAKER
Toolmakers craft precision tools which 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. Diemakers 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. In addition to designing and producing new tools and dies, these workers may also 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 must also be familiar with the machining properties, such as hardness and heat tolerance, of a wide variety of common metals and alloys. As a result, tool and die makers usually must have a much broader knowledge of machining operations, mathematics, and blueprint reading than most other machining workers.
Working from blueprints or instructions, tool and die makers 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, bore, or drill the part as required, checking the accuracy of what they have done to ensure that the final product meets specifications. Finally, these workers assemble the parts and perform finishing jobs such as filing, grinding, and smoothing surfaces.
Modern technology is helping to change the ways that tool and die makers perform their jobs. For example, these workers increasingly use computer-aided design (CAD) to develop products and parts. Specifications from the computer program can then be used to electronically develop drawings for the required tools and dies. The electronic drawings are then processed by a computer-aided manufacturing program to calculate cutting tool paths and the sequence of operations. Once these instructions are developed, computer numerically controlled (CNC) machines usually are used to produce the die. Programs can also be electronically stored and adapted for future use. This saves time and increases worker productivity.
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. Machines have guards and shields that minimize the exposure of workers to moving parts. Tool and die makers 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, as they often spend much of the day on their feet and may do moderately heavy lifting.
Companies employing tool and die makers traditionally operate one shift per day. However, as the cost of new machinery and technology has increased, many employers now have more than one shift. Overtime and weekend work are common, especially during peak production periods.
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 a high degree of patience and attention to detail. Good eyesight is essential. Persons entering this occupation should also be mechanically inclined, able to work independently, and capable of doing work that requires concentration and physical effort.
Tool and die makers learn their trade through 4 or 5 years of education and training—formal apprenticeship, postsecondary programs, or informal on-the-job training. The best way to learn all aspects of tool and die making, according to most employers, is a formal apprenticeship program that combines classroom instruction and job experience. These programs are increasingly rare, however. A growing number of tool and die makers receive most of their formal training from community and technical colleges.
The Tool ans Die Maker apprenticeship program in the Upper Rio Grande Region is administered by the El Paso Moldmaker, Tool and Die Registered Apprenticeship Training Committee. This is a Registered Apprenticeship training program approved by the U.S. Department of Labor. This rigorous training program is governed by well-defined guidelines and standards set by the Department of Labor’s Bureau of Apprenticeship and Training (BAT), relating to the length of an apprenticeship, classroom instruction, job duties and working conditions.
Registered Apprenticeships require a long-term commitment by the apprentice. An apprentice must be sponsored by an employer who administers and pays for the program. A trade union may also be involved in the apprenticeship. Apprenticeships usually last between 1 and 6 years, requiring an extensive investment of time, personnel and financial resources by the company. The employer and apprentice sign an Apprenticeship Agreement, in which the employer agrees to comply with the program standards as outlined by the Department of Labor and make every effort to keep the apprentice employed. The apprentice agrees to faithfully perform required job duties and complete the necessary classroom instruction.
A typical apprentice is a high school graduate at least 16 years of age. Registered Apprenticeships usually last about 4 years, but range from 1 to 6 years, and require 2,000 hours of on-the-job training per year. During this time, apprentices learn the mechanics of the skill under the supervision of journeypersons or masters. On the job, apprentices must demonstrate mastery of the work. Tool and die maker trainees learn to operate milling machines, lathes, grinders and other machine tools. They also learn to use handtools in fitting and assembling tools, gauges, and other mechanical and metal-forming equipment. In addition, they study metalworking processes such as heat treating and plating. As the apprenticeship progresses, the apprentice performs the work under less and less direct supervision.
In addition to the hands-on training provided, the apprentice must attend at least 144 hours of related classroom instruction per year. Classroom training usually consists of mathematics, mechanical drawing, tool designing, tool programming and blueprint reading. Tool and die makers increasingly must learn to use CAD technology and CNC machine tools. Academic and skills tests must be passed before the apprentice can advance through each phase of the program. Upon successful completion of a Registered Apprenticeship, the apprentice receives a Certificate of Completion from the U.S. Department of Labor, a nationally-recognized credential, and journeyperson status.
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.
There are several ways for skilled workers to advance. Some move into supervisory and administrative positions in their firms; others become tool designers or tool programmers; and a few may open their own shops.
Median weekly earnings for tool and die makers who worked full time were $720 in 1996. Most earned between $600 and $910 a week. Ten percent earned less than $480 a week, and the 10 percent with the highest weekly earnings made more than $1,160.
Tool and die makers held about 134,000 jobs in 1996. Most worked in industries that manufacture metalworking machinery and equipment, motor vehicles, aircraft, and plastics products. Although they are found throughout the country, jobs are most plentiful in the Midwest and Northeast, where many of the metalworking industries are located.
Employment of tool and die makers is expected to decline through the year 2006. Nevertheless, jobseekers with the appropriate skills and background should enjoy excellent opportunities, as employers across the Nation report difficulties in finding skilled workers to fill these positions. Many openings will be created each year by tool and die makers who retire. As more of these highly skilled workers retire, employers in certain parts of the country may face pronounced shortages. The shortage of new entrants in the field may be one of the factors retarding employment growth.
Apart from a shortage of new entrants, the projected decline in employment reflects advancements in automation, including CNC machine tools and computer-aided design. CNC machine tools have made tool and die makers more productive, while CAD and CAM have allowed some functions previously performed by these workers to be carried out by a computer and tool programmer. In addition, because precision metal products are a primary component of manufacturing machinery, increased imports of finished goods and precision metal products may lessen the demand for tool and die makers. These workers, however, are highly skilled and play a key role in the operation of many firms. As firms invest in new equipment and modify production techniques, they will continue to rely heavily on skilled tool and die makers for retooling. This fact, coupled with a growing demand for motor vehicles, aircraft, machinery and other products that use machined metal parts, should help to moderate the decline in employment.