FROM PROTOTYPE TO APPROVED TOOL

Sample Validation Process

XRZ uses sample validation to prove a custom cutting tool against agreed part results—before repeat production. Distributors, OEM/ODM buyers and end users share one acceptance plan so trial feedback can revise the tool without ambiguity.

Start validation → RFQ

When a sample tool fits

A sample (trial) tool is appropriate when the print, material and machine path are stable enough to judge geometry—but not yet locked for volume. Typical triggers:

  • New PCD reamer or solid carbide drill design from a drawing
  • Material or silicon content change that alters wear mode
  • Failure mode (breakage, oversize, burr, packing) that needs a controlled countermeasure
  • Distributor quoting an end-user print and needs evidence before stocking

If the requirement is still changing weekly, fix the process notes first—then sample.

What to submit

Drawing & feature

  • Component print (PDF/STEP as available)
  • Finished hole / face tolerances
  • Pre-hole or prior-op notes

Material & volume

  • Alloy / hardness / Si% if known
  • Annual volume and lot size
  • Current tool and failure photos

Machine reality

  • Machine, holder, assembled runout
  • Coolant (flood / through / MQL)
  • Gauge method for acceptance

Field lists that speed quotation: PCD reamer RFQ checklist · solid carbide drill RFQ checklist · Engineering RFQ.

Eight controlled stages

1. Application review

Confirm drawing, material, hole geometry, machine, holder, coolant and the problem the sample must address.

2. Design confirm

Agree tool architecture, diameters, coolant outlets, inspection points and revision ID before metal is cut.

4. Customer trial

Run under agreed speeds/feeds, coolant and holder. Record chips, sound, wear and part results.

5. Feedback data

Return measured size/finish/position, tool photos, chip photos and any parameter changes made on the floor.

6. Revision

If needed, revise geometry or process notes against the same acceptance table—do not mix uncontrolled changes.

7. Release

Freeze the approved revision for repeat supply. Keep the acceptance table with the PO.

8. Lifecycle

Plan regrind/recondition rules and re-validation triggers for critical bores.

Agree on acceptance before the trial

Tool specification

  • Tool dimensions and interface
  • Assembled-tool runout
  • Cutting-edge inspection points

Part result

  • Hole size, position and finish
  • Burr, chip and wear condition
  • Measurement method

Trial conditions

  • Material and machine setup
  • Cutting data and coolant
  • Defined quality or wear endpoint

Fees vs production (how to think about cost)

Sample tools and production tools are priced from scope—geometry complexity, PCD vs carbide, inspection depth and quantity. XRZ does not publish fixed catalog sample prices here because prints differ. Ask for a sample proposal in the RFQ; production pricing follows the released revision and volume. No invented percentage discounts or “guaranteed life” multipliers.

IP and confidentiality

Customer drawings and process notes are treated as confidential project inputs. Share only what is required for design and inspection. For private-label or distributor programs, branding and packaging rules are confirmed in writing before release. See distributor cutting tool program and OEM/ODM cutting tools.

Distributor sampling for an end user

Distributors may request samples on behalf of an end user. Provide the end-user print (or sanitized equivalent), the target machine conditions and who will run the trial. Acceptance still belongs to the part result—not to a catalog claim.

Frequently asked questions

How long does sample validation take?

Lead time depends on geometry, PCD tip work, inspection scope and machine-trial scheduling on the customer side. Confirm the date plan in the RFQ reply—do not assume a universal number.

Do I need a sample for every reorder?

No. After a revision is released, repeat supply follows that drawing. Re-sample when material, machine, holder or tolerance stack changes enough to invalidate prior evidence.

What if the trial fails?

Return measured data and tool/chip photos. XRZ revises against the same acceptance table or recommends splitting the process (for example drill then ream) when combination duty is unstable.

Can XRZ witness the trial?

Remote data review is standard. On-site support is discussed case by case when logistics and NDAs allow.

Which products use this process?

Commonly custom PCD reamers, solid carbide drills and combination drill-reamers—plus other drawing-based tools.

Ready to start validation?

Send the drawing, material and current machining conditions. We will propose the sample scope and acceptance table.

Start validation → RFQ

Also: PCD reamer RFQ checklist · Drill RFQ checklist · Manufacturing & quality evidence