As a premier tool and die manufacturer, we engineer complex progressive dies, transfer tools,
and offer 24-hour ‘closed-loop’ repair services from our 18,000 sq. ft. Dallas facility.
Precision metal stamping is a foundational capability FKI USA has built its business around. From our 104,000-square-foot Texas manufacturing center, we operate as a core, high-volume supplier for major OEMs and Tier 1 partners.
Turnkey tooling for your internal press shop. We engineer and manufacture custom progressive dies and transfer tools, delivered production-ready and validated by Zeiss CMM.
Die crash? Our emergency “Closed-Loop” repair service gets you back online. We reverse-engineer, weld, heat-treat, and grind components in-house—turning weeks of downtime into a 24-hour fix.
The engine of our contract manufacturing. When you stamp with FKI, preventative maintenance is built-in. We handle sharpening and upkeep automatically, ensuring the health of your tool for the life of the program.
In precision manufacturing, the quality of the part is dictated by the quality of the tool. At FKI USA, we don’t rely on external vendors to design, build, or maintain your assets. We control the entire lifecycle in our 18,000-square-foot toolroom.
Equipped with high-speed 15,000 RPM CNCs, and Wire EDM, our vertically integrated toolroom delivers two critical advantages:
We design and build Tier 1 progressive and transfer dies faster than the competition by eliminating third-party queues.
We eliminate weeks of downtime by performing major die repairs onsite. Our “Closed-Loop” repair system often returns a crashed press to production quickly.
Most shops ship damaged dies out for repair, adding weeks to your lead time. We fix them in-house using a validated, three-step restoration process.
We don’t wait for vendors. Our toolroom utilizes Miller TIG welders for intricate surgical repairs. This in-house welding capability allows us to rebuild damaged forming edges and crash-damaged components instantly, ensuring rapid die restoration and minimizing your production downtime.
Welding softens steel; we make it hard again—fast. Unlike shops that ship parts out, we restore hardness onsite using our Vulcan A1750 furnaces. By bringing tool steel hardening and annealing in-house (up to 2012°F), we cut days off the standard repair timeline, delivering a turnkey die repair solution that gets your press running weeks sooner than the competition.
Accuracy is our baseline. Once restored, components are finished on our Brown and Sharpe, Kent Acer and Blanchard grinders to tolerances as tight as 0.0001 inches. Our precision surface grinding ensures every repaired insert matches the original CAD specifications perfectly. From die sharpening to full surface restoration, we validate every dimension before the tool ever returns to the floor.
Our core competency is high-volume, automated stamping. Our fleet includes presses up to 600 tons with massive 132-inch beds and 20,000 lb coil lines to handle heavy-gauge materials (up to 0.250″ thick). This is supported by a full fabrication shop, giving us the power to produce any component for your assembly.
Our 18,000 sq. ft. in-house toolroom is your insurance against downtime. We are not reliant on third-party tool shops. We design, build, and maintain 100% of our production tooling. Our “Closed-Loop Die Repair” process means a line-down crisis can be solved in 24 hours, not weeks.
We prove our precision with data. Our advanced metrology lab is the heart of our US-based quality control, featuring a 96-inch Zeiss CMM for automated inspection and a 7-axis Hexagon Arm for rapid troubleshooting. This lab provides the data for your most demanding PPAP Level 1-5 submissions, FAI reports, and Cpk studies.
We carry the certifications that allow you to sell into regulated markets. Our quality lab features Zeiss CMMs for certification and Hexagon Portable Arms for reverse engineering.
EV & ICE
Turnkey Cosmetic Assemblies
Complete Box Builds
Find quick answers to common questions about our tool & die processes.
Upload a drawing or model of your current tooling challenge. Our engineers will provide a free initial assessment to determine feasibility of new or repair and build to production costs.
