How CNC Tool Refurbishment Saves Aerospace Manufacturers 30% a Year.

Introduction: The Hidden Cost of CNC Tool Replacement

In aerospace machining, precision is non-negotiable. From rivet shavers to reamers and end mills, cutting tools must perform flawlessly on demanding materials like titanium and Inconel. But when these tools wear out, many workshops simply replace them outright.

The problem? Constant replacement drains budgets. For aerospace firms operating on tight margins, this habit can cost thousands each year.

There’s a smarter way: cutting tool refurbishment and recoating.

Inspecting an end mill that has been fully refurbished and coated

What Is CNC Tool Refurbishment?

CNC tool refurbishment is the process of restoring worn cutting tools to their original geometry, performance, and coating. Rather than discarding a dull tool, refurbishment involves:

• Inspection – assessing tool wear and damage.

• Quotation - based on the level of damage to the tool.

• Resharpening – restoring the cutting edge and geometry.

• Recoating – applying advanced coatings to extend tool life.

  
  

The result is a tool that performs like new, but at a fraction of the cost.

Why Aerospace Firms Choose Refurbishment

Aerospace machining is uniquely demanding, with exotic alloys and tight tolerances pushing tools to the limit. Refurbishment delivers major advantages for aerospace firms:

• 30% Cost Savings – by reducing reliance on new tool purchases.

• Extended Tool Life – tools can often be refurbished multiple times.

• Consistent Quality – restored geometry ensures parts meet strict tolerances.

• Sustainability Benefits – reduced waste supports aerospace ESG targets.

• Less Downtime – reliable tools keep production schedules on track.

Refurbishment vs. Replacement: The Cost Comparison

Replacing tools outright may feel convenient, but the costs add up fast:

• Tool Purchases: New tools cost significantly more than refurbishment.

• Scrap & Rework: Worn tools risk damaging expensive aerospace parts.

• Machine Downtime: Unplanned stoppages for tool changes hit productivity.

By contrast, refurbishment restores performance while avoiding these hidden costs. Studies show aerospace firms adopting refurbishment programs typically save around 30% per year on tooling budgets.

BJ Associates: Supporting Aerospace CNC Tooling Needs

At BJ Associates, we specialise in refurbishment and recoating services tailored to the aerospace sector. With decades of experience, we help manufacturers extend tool life and reduce costs while maintaining absolute precision.

Alongside refurbishment, we supply high-performance Dixi Polytool and Kyocera cutting tools — ensuring your workshop has the right tooling solutions, whether you need new, recoated, or refurbished options.

Our goal is simple: to help aerospace manufacturers cut costs without cutting corners.

Ready to cut costs without compromising precision?

👉 Contact BJ Associates today to discuss refurbishment and high-performance tooling solutions.

❓ Frequently Asked Questions About CNC Tool Refurbishment

Q1. How many times can a CNC cutting tool be refurbished?

Most high-quality cutting tools can be refurbished multiple times, depending on their geometry, coating, and level of wear. Aerospace-grade tools are often designed to withstand two to four refurbishment cycles, giving you significantly more life than single-use replacements.

Q2. Does refurbishment affect tool precision?

When done properly, refurbishment restores tools to like-new geometry and tolerances. In fact, many aerospace firms report more consistent performance after using a professional refurbishment service compared to relying on worn tools.

Q3. Is tool refurbishment suitable for aerospace materials like titanium and Inconel? Yes. Refurbished tools can cut hard-to-machine alloys and composites effectively, provided the correct coating and geometry are reapplied during the process. This makes refurbishment especially valuable in aerospace, where material demands are high.

Q4. How much money can refurbishment save compared to buying new tools?

On average, aerospace manufacturers save around 30% annually on tooling budgets by refurbishing instead of replacing. Savings come from reduced tool purchases, less downtime, and fewer scrapped components.

Q5. How do I know if my tool is a candidate for refurbishment?

If a tool shows wear but is not catastrophically damaged (e.g., broken or cracked), it’s likely a strong candidate. BJ Associates offers inspection services to help determine if a tool should be refurbished, recoated, or replaced.