Aerospace cutting tools
Airframes, engines, and structures live or die on tool life and repeatability. RobbJack grinds the flagship tools aerospace shops standardize on: SPS Super Python for titanium and super alloys, FMHV high-velocity end mills for aluminum structures, and K-series slitting saws with thru-coolant arbor solutions for the deep, thin slots nothing else reaches.
The challenges — and how we cut them
1Titanium eats tools when heat builds
Titanium's heat goes into the cutting edge, not the chip — it rewards heavy, rigid setups and tough, sharp tools over raw speed. RobbJack's XG and SPS variable-helix geometries in Tuffy-grade carbide are built for exactly that: with trochoidal toolpaths, a 1/2" 6-flute has run 400 SFM at 75 IPM in Ti-6Al-4V.
2Inconel and super alloys work-harden mid-cut
Never let the tool dwell. The SPS Super Python's all-center-cutting, variable-helix design keeps every flute engaged and has delivered up to a 1000% metal-removal-rate increase in Inconel 718 versus standard tooling — the flagship for engine-alloy roughing.
3Aluminum structures demand extreme MRR — and thin walls
FMHV high-velocity end mills are the aluminum flagship: necked for reach and stable on the fastest spindles made, with peak MRR up to 604 in³/min (1" 3-flute, thru-coolant + DLC). For chatter-prone webs, the Mirror Edge geometry machines walls down to 0.005" thin and 3" tall.
4Deep, narrow slots — blades, rings, fittings
When slot depth passes about 3× the saw thickness you need added clearance, and past 5× you need a K-series saw — double concavity, alternate-tooth chamfer, flat and parallel hubs. Pair it with RobbJack's ultra-precision arbors: 15× the gripping force of screw-cap designs, with thru-coolant (-TC) versions that flood the cut through solid-carbide flanges.
5CFRP delaminates and destroys carbide
PCD is the answer that pays for itself: a PCD-tipped Single Shot drill put 4,000+ clean holes in CFRP wing spars where carbide competitors managed 160, and a CPCD trimming tool cut skin trimming from three operations to one.
The aerospace toolset
SPS
SPS Super Python
The flagship for titanium, Inconel, and stainless — strikes harder, cuts faster, up to 40 HRc.
ExploreFMHV
FMHV High-Velocity Aluminum
Long, chatter-free aluminum cutting at the highest spindle speeds — up to 604 in³/min.
ExploreK-series
K-Series Slitting Saws
Double-concavity, alternate-tooth-chamfer saws for cuts deeper than 3–5× thickness, with thru-coolant arbor systems.
ExplorePCD
PCD Diamond-Tipped Tools
10–30× the life of carbide in CFRP and abrasive layups — drills, routers, and trim tools.
ExploreXF / XG
Titanium End Mills
Variable-helix Tuffy-grade carbide proven at 75 IPM in 6Al-4V.
ExploreThe proof — documented results
- 1000%
- MRR increase — SPS in Inconel 718
- 604 in³/min
- peak aluminum MRR — FMHV thru-coolant + DLC
- $548,290
- saved per year — PCD drilling CFRP wing spars
Aerospace machining questions
What end mill should I use for titanium aerospace parts?
Start with a variable-helix, Tuffy-grade carbide tool — RobbJack's XG for general titanium work or SPS for aggressive roughing. Keep the tool moving (trochoidal paths shine here): a 1/2" 6-flute has run 400 SFM at 75 IPM in Ti-6Al-4V with the right engagement.
How do I cut deep slots in aerospace parts without the saw binding?
Match the saw to the depth ratio. Past about 3× the saw thickness, add clearance (hub or double concavity); past 5×, use a K-series saw — double concavity, alternate-tooth chamfer, flat parallel hubs. A thru-coolant (-TC) arbor floods the cut and clears chips from deep slots, and the nut-clamped arbor design grips with 15× the force of screw-cap arbors.
What's the fastest way to rough aerospace aluminum?
A high-velocity 3-flute like the FMHV with thru-coolant and DLC coating — RobbJack has recorded peak removal rates of 604 in³/min with a 1" tool. For thin webs and walls, switch the finish passes to a Mirror Edge geometry, which holds walls down to 0.005" without chatter.
Do I really need PCD for carbon fiber?
If you're past prototyping, yes — CFRP abrades carbide edges in minutes. In one aircraft program a PCD-tipped drill made 4,000+ holes where carbide managed 160, worth $548,290 a year; a PCD skin-trimming tool collapsed three operations into one.
From the machining lab & case files
Put it on your machine
Send us your toughest aerospace part. Application engineering will spec the tool and the numbers — or quote a special from your print.