In CNC machining, operators are tasked with accurately measuring cutting tools as quickly as possible. Working too slowly can bring production to a crawl, but moving too fast — and risking less accurate readings — can damage product quality.  

For many operators, striking the balance between speed and precision comes with experience. But the tool measuring technology itself, like on-machine tool measurement and offline tool presetting, also play a critical role in productivity.  

To decide which one makes the most sense for your business, here are some factors to consider: 

How much space do you have on the shopfloor? 

If space is a concern, using a more compact but durable entry-level tool presetter can help drive long-term ROI despite layout limitations.  

How long does your tool measurement process take?  

Manufacturers who are focused on speed will likely prefer an offline tool presetter, which works faster and more accurately than human operators. Offline presetters typically shave two to five minutes off set-up time, although this number will vary by machine and process.  If you measure five tools on a ZOLLER presetting and measuring machine, for example, you can reduce the set-up time by more than 40%.  

Additionally, offline tool presetters free up the CNC machine to focus solely on production, which minimizes downtime and allows operators to prepare jobs in advance. 

What gives the best ROI? 

Although on-machine tool measurement does not require any new, upfront costs, you’ll drive more value from a tool presetter. Presetters are a capital investment in manufacturing because they allow your CNC machine to stay focused on production and ultimately produce more parts.  

Many machine shops can quickly make back their investment and drive additional profits with a tool presetter; ProCam Services LLC, for example, attributes a $1 million increase in revenue to a ZOLLER »smile 420«, which measures tools 45% faster than via the machine control system.  

How experienced are your operators? 

Labor shortages for skilled staff have hit manufacturers hard. If you’re struggling to hire experienced workers, it’s worth considering the amount of training you’ll need to provide for each tool measurement method.  

On-machine tool measurement requires skilled machine operators, so training can be longer and more complex than it would be for tool presetting. With ZOLLER tool presetters, for example, each machine is so simple to use that every measurement produces exact values, regardless of the operator.  

What tool measurement data do you need to capture? 

A CNC machine's measuring technology will typically only record tool length. If you’re in high-precision manufacturing, that won’t be enough information to meet tight tolerances. Instead, look for a tool presetter that provides detailed geometry data like length, diameter, angles, radius, and runout for micron-level accuracy.  

Still not sure which tool measurement solution is right for you? Contact the experts at ZOLLER to discuss your manufacturing needs.  
 

Tool Presetting FAQ

What is offline tool presetting?  

Offline tool presetting uses a separate, designated machine called a tool presetter to capture tool data with high-resolution cameras. 

How does offline tool presetting work? 

To measure on a tool presetter, operators will need to remove the tool and take it to the presetter for measurement. Tool data is then transferred to the CNC machine.