AE-TL-N DLC coated end mill improves productivity, surface finish, and reliability on 6063 frame extrusions
Founded in 1971, Special‑Lite is a leading manufacturer of durable, custom commercial entrance systems based in Decatur, Michigan, U.S. The company is the nation’s largest producer of fiberglass reinforced polyester (FRP) doors and supplies high‑performance solutions for high‑traffic environments such as schools, healthcare facilities, and offices.
Special-Lite’s headquarters and legacy manufacturing facility in Decatur, Michigan. Photo courtesy of Special‑Lite.
Special‑Lite continues to expand throughout North America and internationally. Its offerings now include aluminum and fiberglass framing, bathroom partitions, interior glass walls, vestibules, and specialty doors for food processing, healthcare, cleanrooms, and other applications.
Special-Lite custom builds door solutions in a wide range of materials and configurations. Top: aluminum flush door curved entrance. Bottom: wood expressions. Photos courtesy of Special‑Lite.
The company operates two Michigan facilities: its headquarters and legacy plant in Decatur, and a manufacturing facility in Benton Harbor. Decatur produces interior aluminum products, aluminum and hybrid FRP doors and frames, restroom systems, and sliding door solutions. Benton Harbor manufactures pultruded fiberglass doors and frames, composite fiberglass doors, fire‑rated systems, and bullet‑resistant products.
Recently, the Decatur facility encountered excessive tool wear, frequent breakage, and long cycle times while machining 6063 aluminum door frame extrusions. The plant employs more than 100 staff, spans approximately 178,000 square feet, and produces roughly 15,000 units of this specific extrusion annually. Although Special‑Lite has machined frame components since its founding, this application involved a new CNC router designed for the extrusions. The parts require profile milling with tight assembly tolerances of ±0.4 mm and clean edge finishes to meet both aesthetic and structural requirements.
The original 3/8‑inch, 3‑flute solid‑carbide end mill from a competitor delivered short tool life, frequent chipping, and breakage, leading to inconsistent quality and high tooling costs. After a recommendation and onsite review from a cutting tool distributor, Special‑Lite evaluated OSG’s tooling. OSG recommended the 3/8″ × 1‑1/8″ AE‑TL‑N 3‑flute DLC‑coated end mill (EDP# 86300809).
The AE‑TL‑N DLC‑coated carbide end mill is highly effective for non‑ferrous materials such as aluminum alloys that demand welding resistance and lubricity.
The AE‑TL‑N DLC‑coated carbide end mill is engineered for non‑ferrous materials requiring high welding resistance and lubricity. Its sharp cutting geometry minimizes burrs and improves surface finish. A unique flute form ensures smooth chip evacuation, while a large‑core design enhances rigidity and reduces chatter. The center‑cut configuration allows plunging, and OSG’s DLC‑SUPER HARD coating delivers extended tool life. The series is available in square, sharp corner, radius, and chipbreaker styles for diverse applications.
Machining an aluminum door frame profile with OSG’s AE‑TL‑N 3‑flute end mill.
Under previous conditions, the competitor tool ran at 9,500 RPM and 114 IPM, with a cycle time of 48 seconds per part and a cost of $5.26 per part. By comparison, the AE‑TL‑N operated at 13,242 RPM and 159 IPM, cutting cycle time to 16 seconds and cost to $0.91 per part.
The result: an 82.7% reduction in cost per part. Across 15,000 annual units, Special‑Lite saves an estimated $65,000 and approximately 133.5 hours of machine time. Tool life increased fivefold, from 20 parts per tool to 100.
From left: Special-Lite product development staff engineer John McCauslin, Special-Lite machinist Connor Olkowski and Special-Lite CNC programmer Craig Walls at the company’s Decatur manufacturing facility in Michigan.
“These OSG end mills are great,” said Special‑Lite machinist Connor Olkowski. “Our other tools would snap in half, but these keep going.”
For more information on OSG’s AE-TL-N DLC coated end mill for non-ferrous materials, OSG USA and Special-Lite
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