TOOL & DIE DESIGN & BUILD
Tool and Die
In-House Tooling for Speed, Control, and Stability
Zakobe designs, builds, and maintains stamping tooling entirely in-house, allowing direct control over quality, lead time, iteration speed, and long-term production stability.
This capability is central to our ability to support electronics and power-system components with tight tolerances and evolving design requirements.
In-House Tool Design
All stamping tools are designed internally by dedicated die design engineers.
Tooling Design Approach
- Tooling is engineered specifically for the material, geometry, and production volume of each part
- Designs emphasize repeatability, serviceability, and long-term dimensional stability
- Customer specifications are met as written unless manufacturability risks require discussion
Design Software & Methods
- KeyCreator CAD
- Proprietary internal tooling design standards developed specifically for electronics-scale components
Tool designs are controlled documents and updated as changes occur.
Tool Build Capabilities
Zakobe builds tooling in-house using:
- Wire EDM
- Manual machining equipment
- In-house heat treating
When timelines require acceleration, select local partner machine shops may assist with non-critical blank components under Zakobe engineering control.
Final fitting, validation, and approval remain internal.
Tool Validation & Release
Before release to production, tooling undergoes:
- Engineering review for fit, form, and function
- Tryout using production-equivalent material
- Validation on live production equipment
Tooling is not released until it meets defined performance and quality requirements.
Tool Change Control
- Tool modifications are documented and revision-controlled
- Design updates are retained with the tool record
- Changes are reviewed to ensure no unintended downstream effects
This ensures long-term traceability and repeatability across production runs.
Tool Life & Maintenance
Wear Monitoring
Tool wear is monitored through:
- Burr formation
- Feature completeness
- Dimensional drift
Maintenance Triggers
- Any non-conforming condition triggers evaluation
- Preventive maintenance is performed based on observed wear trends
- Maintenance may occur pre-run or post-run depending on risk level
Tool Life Tracking
- Tool life is tracked by hit count for production programs
- Performance history informs future tooling design and maintenance intervals
Risk Mitigation & Redundancy
For high-volume or critical programs, Zakobe implements risk-reduction strategies including:
- Stocked spare inserts or components
- Quick-change tooling elements where applicable
- Rapid in-house repair capability
In many cases, tooling can be repaired and returned to service within hours, not days or weeks.
Root causes of premature tool failure are investigated and addressed to prevent recurrence.
Strategic Advantage for Customers
In-house tooling allows Zakobe to:
- Shorten tooling lead times
- Respond rapidly to design changes
- Reduce dependency on overseas tool builders
- Minimize downtime during production disruptions
- Maintain tighter control over part quality
This capability is especially valuable for electronics and medical programs where iteration speed and stability are critical.