Horn DM40 Modular PCD End Mill Cuts Tooling Costs

Aluminium and plastics machining Interchangeable-head PCD end mill reduces machining costs

2026-09-25 Source: Horn 1 min Reading Time

Related Vendors

Replacing the cutting head while retaining the carbide shank could lower tooling costs when machining aluminium and plastics. Horn’s modular DM40 PCD end mill combines interchangeable heads with cutting tips that can be resharpened up to twice.

Horn’s new DM40 series end mills comprise a solid carbide toolholder and an interchangeable steel head with brazed-on PCD cutting tips.(Source: Horn) — Horn’s new DM40 series end mills comprise a solid carbide toolholder and an interchangeable steel head with brazed-on PCD cutting tips.
(Source: Horn)

German cutting tool manufacturer Horn has introduced a new, modular range of PCD (polycrystalline diamond) end mills for machining aluminium, plastics and other materials in groups N (non-ferrous) and O (non-metallic). The system combines a reusable, solid carbide shank and a PCD-tipped, interchangeable steel head. Availability in the UK and Ireland is through Horn Cutting Tools, Ringwood.

The manufacturer has designed the DM40 system to conserve resources and ensure cost-effective machining. The end cutting edges of the mill are among the main wear zones, while peripheral cutting edges longer than twice the tool diameter are susceptible to high lateral cutting forces, vibration and chipping. The ability to change just the head reduces follow-on costs compared with conventional monobloc tools, especially as the worn, brazed-on, PCD tips can be resharpened up to twice.

By designing the cutter with a separate shank and head, Horn has ensured that the consumable cost is not only lower but also more predictable, making the tool system ideal for series production runs and automated lines. Users can quickly replace the head module on-site, so the tool is rapidly back into service, maximising spindle uptime.

The head is attached to the shank by a central clamping screw that provides both a force-fit and a form-fit connection. Colour coding facilitates the identification of components and a poka-yoke principle prevents assembly errors. The rigidity of the interface ensures precise machining, whether using a new or a resharpened tool, and the large axial rake angle enables smooth cutting and produces an excellent surface finish.

(ID:50968364)

Subscribe to the newsletter now

Don't Miss out on Our Best Content

Business E-mail

Please enter a valid mailadress.

By clicking on „Subscribe to Newsletter“ I agree to the processing and use of my data according to the consent form (please expand for details) and accept the Terms of Use. For more information, please see our Privacy Policy. The consent declaration relates, among other things, to the sending of editorial newsletters by email and to data matching for marketing purposes with selected advertising partners (e.g., LinkedIn, Google, Meta)

Date: 08.12.2025

Naturally, we always handle your personal data responsibly. Any personal data we receive from you is processed in accordance with applicable data protection legislation. For detailed information please see our privacy policy.

Consent to the use of data for promotional purposes

I hereby consent to Vogel Communications Group GmbH & Co. KG, Max-Planck-Str. 7-9, 97082 Würzburg including any affiliated companies according to §§ 15 et seq. AktG (hereafter: Vogel Communications Group) using my e-mail address to send editorial newsletters. A list of all affiliated companies can be found here

Newsletter content may include all products and services of any companies mentioned above, including for example specialist journals and books, events and fairs as well as event-related products and services, print and digital media offers and services such as additional (editorial) newsletters, raffles, lead campaigns, market research both online and offline, specialist webportals and e-learning offers. In case my personal telephone number has also been collected, it may be used for offers of aforementioned products, for services of the companies mentioned above, and market research purposes.

Additionally, my consent also includes the processing of my email address and telephone number for data matching for marketing purposes with select advertising partners such as LinkedIn, Google, and Meta. For this, Vogel Communications Group may transmit said data in hashed form to the advertising partners who then use said data to determine whether I am also a member of the mentioned advertising partner portals. Vogel Communications Group uses this feature for the purposes of re-targeting (up-selling, cross-selling, and customer loyalty), generating so-called look-alike audiences for acquisition of new customers, and as basis for exclusion for on-going advertising campaigns. Further information can be found in section “data matching for marketing purposes”.

In case I access protected data on Internet portals of Vogel Communications Group including any affiliated companies according to §§ 15 et seq. AktG, I need to provide further data in order to register for the access to such content. In return for this free access to editorial content, my data may be used in accordance with this consent for the purposes stated here. This does not apply to data matching for marketing purposes.

Right of revocation

I understand that I can revoke my consent at will. My revocation does not change the lawfulness of data processing that was conducted based on my consent leading up to my revocation. One option to declare my revocation is to use the contact form found at https://contact.vogel.de. In case I no longer wish to receive certain newsletters, I have subscribed to, I can also click on the unsubscribe link included at the end of a newsletter. Further information regarding my right of revocation and the implementation of it as well as the consequences of my revocation can be found in the data protection declaration, section editorial newsletter.