Most of our customers drop off a box of dull endmills and pick up a box of sharp ones. What happens in between is a process most people have never seen — and it’s a lot more precise than most people expect.
This is what actually happens to your tools between drop-off and delivery.
Step 1: Receiving and Inspection
Every tool that comes through our door gets inspected before it goes anywhere near a grinder.
We check for chips, cracks, broken flutes, and excessive wear. We measure diameters and note geometry. We’re looking for two things: first, is this tool resharpeable — is it structurally sound enough to be worth the work? Second, what does the original geometry look like so we know what we’re grinding back to?
For standard tools from major manufacturers — Kennametal, Seco, Sandvik, OSG, Niagara, Garr — we already have the geometry specs on file. For custom or unusual tools, we measure and document the existing geometry before we touch it.
Tools that are chipped beyond repair, broken, or so worn they’ve lost too much diameter get flagged and the customer is notified. We don’t sharpen tools that aren’t worth sharpening — that’s not good for anyone.
Step 2: Ultrasonic Cleaning
Before grinding, every tool goes through our Omega Sonic ultrasonic cleaning tank.
Ultrasonic cleaning uses high-frequency sound waves to create microscopic cavitation bubbles in a cleaning solution. Those bubbles implode against the tool surface, removing coolant residue, chips, built-up material, and contamination from every surface — including the flute valleys and cutting edges that are impossible to reach with a brush or rag.
A clean tool gives us an accurate look at the actual cutting edge condition, and it means the grinding wheel isn’t contaminated by residue during the regrind.
Step 3: CNC Grinding on the ANCA FX7
This is where the precision work happens.
We run four ANCA FX7 CNC tool and cutter grinders, each equipped with Fanuc loaders and Ultra Laser measurement systems. These are 5-axis CNC grinders — the same class of machine used to manufacture new carbide tooling from blank stock. In fact, we use them to manufacture Frost CNC Tooling in house.
The ANCA CIM 3D software allows us to program exact tool geometries — helix angles, relief angles, point geometry, gash angles, edge preps — and grind to those specs with micron-level repeatability. Every flute, every relief, every edge is ground to match the original OEM geometry.
For standard tools, this means your endmill comes back performing exactly as it did when it was new. For custom tools, we can grind to a customer-supplied print, a sample tool, or a geometry we’ve reverse engineered from your application.
The Fanuc loaders allow us to run large batches overnight — hundreds of tools processed without operator intervention, each one ground to the same spec as the last. That’s important for shops running high-volume production who need consistent, predictable tool performance across an entire batch.
Step 4: Post-Grind Inspection
After grinding, every tool goes through inspection before it leaves the shop.
We use a combination of optical comparators, video inspection systems, and precision measurement equipment:
- S-T Industries and Dorsey optical comparators at 20× for visual edge inspection and geometry verification
- PG1000 video inspection system at up to 144× for detailed edge examination and measurement
- Vollmer N173 concentric measuring system for runout verification
- Mitutoyo calipers and micrometers for diameter and length confirmation
We’re checking that the geometry matches spec, the edge is clean and sharp with no grinding burn or chatter marks, and runout is within tolerance. A tool that doesn’t pass inspection goes back to the grinder.
Step 5: Coating (Optional)
If a customer wants their tools recoated — to restore the coating removed during resharpening, or to add a coating for the first time — this happens after the regrind and inspection.
We offer AlTiN, ZrN, TiN, TiLAN, DLC, AlCrN, and TiCN coatings, each suited to specific materials and applications. The right coating can significantly extend tool life between resharps — sometimes by 3 to 5 times compared to an uncoated tool in the right application.
Coating selection depends on what you’re cutting. Aluminum and non-ferrous metals do best with ZrN. High-temperature alloys and dry cutting want AlTiN. Titanium and exotic alloys benefit from TiLAN. We’ll help you pick the right one if you’re not sure.
Step 6: Final Cleaning, Packaging, and Delivery
After inspection — and coating if applicable — tools get a final clean and are packaged for return.
We offer pickup and delivery within 100 miles of the Twin Cities, covering most of Minnesota and into western Wisconsin. Most orders turn around in one week. Rush turnaround is available when needed.
Why This Process Matters
The difference between a properly resharpened tool and a poorly resharpened one isn’t just edge sharpness — it’s geometry accuracy. A tool with incorrect relief angles, wrong helix geometry, or uneven flutes will cut poorly, break prematurely, and produce inconsistent surface finishes, even if the edge feels sharp.
The reason we invested in ANCA FX7 equipment — the same machines used to manufacture premium tooling — is that accurate geometry requires accurate machines. You can’t grind a tool to OEM spec on a manual grinder with a skilled operator and a good eye. You need CNC control, laser measurement, and proven programming.
That’s what we bring to every tool that comes through our shop — whether it’s one endmill or five hundred.
Ready to put a sharper edge on your operation? Call us at 763.786.9652 or request a free quote online.