As OEMs and suppliers in the semiconductor industry strive to meet the ever-growing demand for microchips, the pressure to reduce costs while maintaining quality intensifies. At West Ohio Tool Co., we've partnered with industry leaders to develop innovative tooling solutions that not only meet but exceed these challenges.
Here's how we've helped our clients achieve significant cost savings without compromising on performance.
1. Extend Tool Life with Advanced Materials
Traditional carbide drills often struggle in semiconductor applications, where the material’s hardness and sensitivity lead to rapid wear, frequent tool changes, and costly downtime. In a recent industry evaluation involving five suppliers, West Ohio Tool Co. (WOT) was the only one able to produce a polycrystalline diamond (PCD) drill that successfully cut the first hole and maintained stable performance over extended runs. Other vendors offered PCD drills, but differences in design, edge preparation, and manufacturing precision limited their effectiveness.
By refining diamond grain orientation, optimizing cutting geometry, and controlling the brazing process, West Ohio Tool Co. removed the key barriers that typically cause chipping or early failure. The result was a tool that allowed a major automotive OEM to move from 25,000 holes per drill to more than 1,000,000, reducing downtime and cost per hole without compromising quality or process stability.
2. Optimize Tooling Geometry for Enhanced Performance
When off-the-shelf tools reach their limits, purposeful innovative engineering makes the difference.
A manufacturer machining a challenging ceramic-based semiconductor substrate faced repeated tool breakage and extended cycle times. By analyzing the material’s characteristics and developing a custom drill geometry tailored to its unique hardness and brittleness, engineers eliminated the chipping that had stalled production, shortened machining cycles, and maintained the tight tolerances the application required.
3. Implement Resharpening Programs to Maximize Tool Value
Rather than discarding used tools, our resharpening programs allow clients to extend the life of their tooling investments. By refurbishing tools to like-new condition, manufacturers can achieve consistent performance and significant cost savings over time.
The strategy is designed to maximize sustainability while reducing costs.
4. PCD Drill Recycling Program: Maximizing Return on Spent Tooling
End-of-life PCD drills often present a hidden cost. Standard recyclers typically classify these tools as “dirty carbide” because of their mixed diamond–carbide composition, which significantly lowers the value of the reclaimed material.
WOT offers a dedicated recycling program designed to protect that value. By carefully removing the PCD segments before the carbide is processed, our team ensures the remaining material qualifies as clean carbide, allowing customers to receive a higher payout for their worn tooling and capture more of the original investment.
Ready to Innovate?
Explore our semiconductor case studies to learn more about how we've helped clients achieve remarkable results. If you're looking to lower your cost per part without cutting corners, then work with a tooling partner who innovates solutions that transform semiconductor manufacturing; cutting costs, boosting efficiency, and driving breakthrough innovation.
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