Key Responsibilities and Required Skills for Die Maker

🎯 Role Definition

A Die Maker (Tool & Die Maker) is a skilled tradesperson responsible for constructing, repairing, modifying, and maintaining stamping dies, progressive dies, transfer dies, and other precision tooling used in production. The Die Maker supports die tryouts, press setup and optimization, troubleshooting die performance, and collaborates with engineers and production teams to improve part quality, reduce cycle times, and extend tool life. This role requires mastery of bench tooling, machining (CNC and manual), EDM, grinding, welding/brazing, and precision inspection, along with a strong safety and continuous improvement mindset.

📈 Career Progression

Typical Career Path

Entry Point From:

Machinist or CNC Operator transitioning to tooling work
Tool & Die Apprentice completing on-the-job training programs
Press Operator or Setup Technician promoted into die room responsibilities

Advancement To:

Senior Tool & Die Maker / Journeyman Die Maker
Toolroom Supervisor or Die Maintenance Supervisor
Manufacturing Engineer or Tooling Engineering Lead

Lateral Moves:

Maintenance Technician / Industrial Mechanic
CNC Programmer / CNC Setup Specialist

Core Responsibilities

Primary Functions

Read, interpret, and apply engineering drawings, blueprints, and GD&T callouts to accurately build, set up, and modify progressive dies, transfer dies, and single-hit dies to customer specifications and manufacturing tolerances.
Fabricate, wire-EDM, mill, lathe, grind, and hand-fit precision die components using CNC machines, manual mills, lathes, surface grinders, and toolroom equipment to achieve dimension and surface finish requirements.
Assemble and bench-fit dies, including fitting punches, pilots, lifters, springs, cam-driven components, and bushing alignments to ensure full die function and repeatability during tryout.
Perform die tryout and first-article verification on stamping presses, systematically troubleshoot issues such as burrs, misfeeds, part distortion, and premature wear, and implement corrective actions to meet quality targets.
Program and operate wire EDM and die-sinking EDM machines for die detail production and repair, including electrode prep, parameter selection, and finish passes for hardened tool steels.
Conduct press setup and tooling changes on mechanical and hydraulic presses, including alignment, tonnage verification, cushion settings, and safety guarding checks to guarantee safe operation and optimal cycle time.
Repair, recondition, and maintain worn or damaged dies using welding (TIG, MIG), brazing, metal stitching, hard-facing, and post-repair machining to extend tool life and reduce downtime.
Perform precision grinding and lapping of die components and maintain surface finish and parallelism of mating surfaces to minimize scrap and ensure consistent part dimensions.
Set up and program CNC milling and turning centers for tool and die components, create or revise CNC programs (Mastercam, Fusion 360, or similar), and optimize feeds/ speeds for tooling life and accuracy.
Apply metallurgy and heat-treat knowledge to select appropriate steels, recommend hardening and tempering cycles, and verify hardness for critical die components and tooling.
Perform dimensional inspection using micrometers, calipers, height gauges, CMM, optical comparators, and other metrology tools to validate tooling accuracy and maintain inspection records for traceability.
Use precision measurement and gaging techniques to certify first-off parts and implement corrective tooling adjustments when deviations are discovered during production.
Maintain and update die maintenance logs, tooling databases, bill of materials, and revision history using ERP/MRP systems, enabling controlled change management and rapid die changeovers.
Work collaboratively with design and manufacturing engineers to implement die design improvements, optimize material usage, minimize scrap, and reduce cycle times using DFMA and Lean principles.
Participate in root cause analysis (8D, PDCA) for die-related production issues, lead corrective/preventive actions, and track metrics for die performance and mean time between repair (MTBR).
Plan and prioritize die rebuilds, preventive maintenance schedules, and spare parts procurement to minimize unplanned downtime and maintain production readiness.
Train and mentor apprentices, junior die makers, and pressroom setup technicians on tooling best practices, safe handling, inspection methods, and machine setup techniques.
Ensure strict compliance with shop safety standards, safe lockout/tagout procedures during die changes and repairs, and proper use of rigging and lifting equipment when handling heavy tooling.
Coordinate with vendors for specialized repairs, heat-treat services, plating, coating (e.g., Nitride, Titanium Nitride), and custom component fabrication to meet critical tooling timelines.
Implement continuous improvement initiatives in the toolroom, including 5S organization, standardized operating procedures for common die types, and tooling lifecycle cost reduction projects.
Evaluate and recommend tooling design changes for manufacturability, including redesigns to reduce secondary operations, simplify set-up, and improve scrap yield in high-volume stamping.
Maintain stock of consumables and critical spares (springs, bushings, wear plates) and manage tooling kitting for scheduled jobs to accelerate die changeovers and minimize production delays.

Secondary Functions

Support production planning by estimating die repair and setup times, advising on required press capacity, and sequencing workload to meet customer delivery schedules.
Document best practices, standard operating procedures, and tooling lessons learned to institutionalize knowledge and reduce rework across the die room and press floor.
Assist quality and process engineering teams with capability studies, fixture qualification, and corrective action implementation to improve part tolerances and reduce nonconformance incidents.
Participate in safety audits, tooling FMEAs, and continuous improvement kaizen events focused on die reliability, operator ergonomics, and cycle time reduction.
Collaborate with purchasing to evaluate and source third-party tooling vendors, reviewing quotes, and ensuring supplier capabilities meet specification and turnaround needs.
Provide technical input during new product introductions (NPI), including feasibility reviews, tooling cost estimates, and prototype die builds to support pre-production validation.
Maintain a clean, organized toolroom environment, enforce 5S standards, and ensure all tooling is properly tagged, stored, and traceable for rapid deployment.
Aid in pressroom troubleshooting during high-impact production runs, providing on-call support during die tryouts or production escalations to restore run rate quickly.
Maintain training records and competency checklists for die room personnel to ensure a qualified workforce capable of performing complex rebuilds and tryouts.
Track tooling KPIs (mean time to repair, uptime, scrap rates) and provide periodic reports to manufacturing leadership to drive investment decisions and continuous improvement prioritization.

Required Skills & Competencies

Hard Skills (Technical)

Expert ability to read and interpret engineering drawings, blueprints, and GD&T to build and verify complex die geometry.
Proven experience with CNC milling and turning—programming, setup, and operation of 3-, 4-, and 5-axis machines.
Proficiency in wire EDM and die-sinking EDM operation, including electrode fabrication, spark gap control, and surface finish management.
Advanced manual machining skills: surface grinding, bench work, jig grinding, reamers, broaching, and precision fitting.
Hands-on die repair techniques: TIG/MIG welding, brazing, metal stitching, hardfacing, and post-weld machining.
Experience with die tryout on mechanical, servo, and hydraulic presses, including tonnage calculations, cushion setups, and cam timing adjustments.
Metrology and inspection expertise using micrometers, vernier calipers, height gauges, CMM programming/operation, and optical comparators.
Knowledge of heat treat processes, tool steel selection, hardening/tempering, case hardening, and managing tooling distortions after heat treatment.
Familiarity with CAD/CAM tools (e.g., SolidWorks, AutoCAD, Mastercam) to read models, generate programs, and collaborate on tooling revisions.
Practical understanding of stamping processes—progressive, transfer, and deep draw tooling—and their impact on die design and maintenance.
Strong working knowledge of Lean Manufacturing, 5S, TPM, and continuous improvement techniques applied to toolroom operations.
Competence with ERP/MRP systems to log tooling history, manage work orders, and track spare part inventory.

Soft Skills

Excellent problem-solving and analytical thinking to diagnose complex die and press issues under production constraints.
Strong attention to detail and commitment to precision to meet tight tolerances and high-quality standards.
Effective communication and collaboration skills to work cross-functionally with engineers, production operators, quality, and purchasing.
Time management and prioritization skills to balance competing repair requests, preventive maintenance, and NPI support.
Mentoring capability to train apprentices and junior technicians and transfer institutional tooling knowledge.
Safety-first mindset with strict adherence to lockout/tagout and shop safety protocols.
Adaptability and resilience in fast-paced production environments with changing priorities.
Customer-focused orientation to support internal and external stakeholders with responsiveness and technical credibility.
Continuous improvement mindset to identify and implement process improvements that lower costs and improve uptime.
Detail-oriented documentation skills to maintain accurate records, BOMs, and revision control for tooling assets.

Education & Experience

Educational Background

Minimum Education:

High school diploma or GED with vocational training in toolmaking, machining, or a related technical trade.

Preferred Education:

Associate degree or technical certificate in Tool & Die Technology, Precision Machining, or Manufacturing Technology.
Completion of an accredited Tool & Die apprenticeship program or journeyman certification.

Relevant Fields of Study:

Tool & Die Technology
Precision Machining / Machinist
Manufacturing Engineering Technology
Industrial Maintenance / Mechanical Trades

Experience Requirements

Typical Experience Range: 3–10 years of hands-on toolroom, die making, and die repair experience.

Preferred: 5+ years of progressive experience building, repairing, and maintaining high-volume progressive and transfer dies, with demonstrated experience in CNC, EDM, die tryout, and shop leadership or mentorship responsibilities.