U.S. Broach Tool

More Than Broaching – A Legacy of Precision Since 1916

U.S. Broach Tool is a top-quality broach tooling manufacturer dedicated to giving you that power through custom broach tooling solutions that cut above the rest. We specialize in both advanced Spirex and conventional round broach tools, as well as surface broaches, form broaches, and keyway broaches – all designed and manufactured to exacting standards.

As part of the Crankshaft Machine Group (est. 1916), our legacy of craftsmanship and innovation runs deep. From the first concept sketch to the final grind, every broach tool we create is engineered for strength, accuracy, and durability. We utilize state-of-the-art 6-axis CNC grinding machines made by Star SU to ensure each tooth on your tool is perfectly formed. The result? Specialty broach tooling that delivers exceptional performance and longevity, stroke after stroke.

And we don’t just deliver great tools, we keep them great. U.S. Broach offers both CNC and manual sharpening, reconditioning, and repair services with a standard three-day turnaround.

Expedited overnight broach tool sharpening is available to minimize downtime.

Broach Tooling

Broach tools are the unsung heroes of the manufacturing world. When you need to cut a precise shape or spline in a single pass, nothing beats a broach. Instead of requiring multiple machining operations or slow, iterative passes, a broach tool does it all in one stroke. This means you achieve exceptionally tight tolerances, uniform finishes, and repeatable quality every time, a competitive edge for any business seeking efficiency and consistency.

A properly designed broach tool can turn a difficult manufacturing step into a smooth, quick operation. Need a perfectly shaped keyway or an internal gear profile? A custom broach will produce that complex geometry faster and more accurately than milling, EDM, or other processes in many cases. Broaching not only saves time, it also extends tool life of your other machines by consolidating work into one robust tool.

Broach tooling enables faster production, greater precision, and lower cost per part. It’s the secret weapon when high-volume, high-accuracy output is non-negotiable.

Broaching tools make specialty manufacturing possible. Some shapes like the fir-tree slots in turbine discs or the multi-spline drive in an automotive transmission – must be broached to achieve the required precision and surface finish. By investing in quality broach tooling, manufacturers in automotive, aerospace, defense, and other sectors ensure they can create components that meet strict standards and perform under extreme conditions. When performance and precision are paramount, broaching is often the answer.

Why U.S. Broach?

Choosing a broach tooling manufacturer is a critical decision – the quality of your tools directly affects the quality of your products (and your bottom line). We offer an unmatched combination of expertise, technology, and customer focus.

✅ Uncompromising Precision & Quality

We build every broach tool to meet the tightest tolerances and highest quality standards. Our precision engineering process, including CNC finishing and meticulous inspections, means your tool arrives ready to perform flawlessly. Many manufacturers talk about quality – we live it, measuring success in thousandths of an inch and ensuring durability that outlasts the competition. Each tool is an investment in excellence that pays off in longer tool life and superior parts for you.

✅ Custom Solutions, Not Catalog Items

Your needs aren’t generic, so neither are our tools. As a true custom broach tooling provider, we don’t force you to compromise with “close enough” standard tools. Instead, we craft a solution around your specific application, whether it’s a unique shape, an unusual material, or a new efficiency target. This tailored approach means you get better performance and often a lower total cost (because a tool built for your job will last longer and cut better). Our engineering team thrives on challenge – if you have a broaching problem, we have the creativity and know-how to solve it.

✅ End-to-End Manufacturing & Support

Unlike some who might outsource key steps, U.S. Broach Tool controls the entire manufacturing process in-house. This vertical integration ensures quality at every step, from raw material to finished product. It also gives us agility – we can ramp up, adjust, and deliver faster because we’re not waiting on third parties. And our job isn’t done when we ship the tool. We stand by you with training, troubleshooting, and reconditioning services for the life of the tool. We offer peace of mind: one team accountable for everything, always here for you.

✅ Fast Turnarounds & Reliable Delivery

In manufacturing, time is money. We respect your deadlines and have structured our operations to deliver on time, every time. Need a new broach quick? Our efficient design-build process and in-house capacity allow for some of the fastest lead times in the industry for custom tools. Plus, our same day sharpening service keeps your existing tools in rotation with minimal downtime. Many customers come to us after being let down by long lead times elsewhere – and they stay because we keep their production on schedule.

✅ Industry Expertise & Innovation

When you work with U.S. Broach Tool, you tap into over 100 years of collective experience in broaching and machining. We’ve been at the forefront of broach tool innovation – from adopting the latest CNC technologies to developing proprietary broach geometries that cut more efficiently. Our team has tackled projects across automotive, aerospace, energy, and beyond, giving us insight into best practices for each field. We bring this industry depth to every new project, advising you on how to get the most out of your broaching operation. We don’t just make tools; we help you make better products with those tools.

✅ Integrated Machine & Tooling Knowledge

Here’s a major differentiator: we also build broaching machines through U.S. Broach Machine. That means we understand the entire broaching system inside and out – the forces, the fixturing, the automation. This knowledge makes our tooling design smarter. We anticipate how the tool will interact with the machine and the workpiece, ensuring safer operation and optimal cutting conditions. It also means if you have a tricky setup, we can likely tweak either the tool or recommend machine adjustments to get it right. Very few tooling suppliers can offer this holistic perspective. It’s like having a pit crew that designs both the engine and the tires of a race car to work perfectly together.

Each of these points adds up to one thing: unmatched value for our customers. We know you have choices when it comes to broach tooling, which is why we go above and beyond to earn and keep your trust. From the first call to the final cut, we are committed to delivering an outstanding experience and measurable results for your business.

Custom Broach Tooling

Not all broach tools are created equal. We pride ourselves on designing and building the exact broaching tool you need for your unique application. Our range of specialty broach tooling covers virtually every configuration and profile imaginable. Here’s a look at the types of broach tools we provide and what they can do for you:

• Round & Spirex Broaches: We manufacture round broaches – including Spirex helical broaches – ideal for cutting perfectly round holes, splines, or spiral grooves with ultra-tight tolerances. Spirex broach tooling features a gentle spiral in the tool’s gullet design, enabling smoother cutting action and reduced stress. These tools excel at internal spline broaching and can handle hard materials while maintaining precision.

• Spline & Form Broaches: For internal forms like involute splines, key splines, rectangles, hexagons, or other custom profiles, our spline and form broaches are the go-to solution. Each tool is custom-built to cut the exact profile you need in one pass. Whether it’s an involute spline for a transmission sun gear or a star-shaped form for a specialty fastener, we’ll design the broach teeth progression to carve it out flawlessly. These broaches often incorporate sections for roughing, semi-finishing, and finishing to achieve the perfect profile and finish by the end of the stroke.

• Surface & Slot Broaches: When you need to cut an external surface or slot, such as a flat surface on a part or a dovetail slide, surface broaches come into play. Our surface broach tools (sometimes called slab broaches) remove material from an exterior surface with each progressive tooth. They are commonly used for parts like hand tool components (e.g., the flat of a wrench) or for creating slots and channels in machinery components. We design surface broaches with rigid backings and precise tooth geometry to ensure a consistent depth and finish across the entire surface.

• Keyway Broaches: Cutting keyways in gears, hubs, and pulleys is made easy with our keyway broach tools. We offer standard keyway broaches (for common key sizes) as well as custom-width broaches for unique applications. These tools are used with guiding bushings to cut the slot accurately through a bore. If you’re a manufacturer of drive train components or hydraulic pumps, you know a precise keyway is critical – and our broaches will deliver that accuracy time and again. We also stock some common keyway broach sizes for immediate delivery when time is of the essence.

• Specialty & Custom Profiles: Have a truly unique shape or an uncommon application? That’s our specialty. From gear-tooth broaches that cut internal gears, to rifling broaches for firearm barrels, to double-D hole broaches and beyond – we’ve either made it or we can make it. Our engineering team loves a challenge. We combine deep knowledge of cutter geometry with advanced CAD/CAM design to create custom broach tools for one-of-a-kind projects. When off-the-shelf won’t cut it (literally), U.S. Broach Tool will design a tool that does.

In every category of broach tool, customization is the name of the game. We tailor the material (often premium tool steels like M2, PM M4, or even exotic alloys), the tooth size progression, the coating (TiN, TiAlN, etc. for extended life), and the dimensions to suit your job. The result is a tool that integrates seamlessly with your machine and your workpiece, giving you optimum cutting performance.

Industries Served

Here are some of the key industries we serve and how our broach tools make a difference. Our experience across these sectors means we understand the challenges you face and can deliver broach tooling that meets those challenges head-on.

Services & Capabilities

Our commitment to customers goes beyond just delivering a tool. We offer a full suite of services and capabilities to support your operation at every stage, from initial concept through ongoing production. Here’s how we take your broach tooling project from start to finish and beyond:

• Design & Engineering from Concept: It all begins with your unique requirements. Our experienced engineers work closely with you to understand the part you need to broach and the outcomes you expect. Using advanced CAD/CAM software and decades of broach design know-how, we design custom broach tooling that will produce your desired geometry flawlessly. Tooth by tooth, we map out the broach’s profile, including rake angles, reliefs, and chip breakers, to optimize cutting efficiency. Whether you have detailed part drawings or just an idea, we can develop a broach tool concept that fits. We’ll even consult on tweaks to your part design if it can improve broach-ability and extend tool life. This collaborative, consultative engineering approach ensures the tooling you get is exactly what you need.

• In-House Precision Manufacturing: Once the design is approved, our manufacturing team brings it to life under one roof. U.S. Broach Tool’s production floor boasts precision machining centers, and 6-axis CNC grinding machines dedicated to broach manufacturing. We cut no corners (except the ones you need on your part!). Every broach is machined from premium tool steel, then heat treated to achieve the hardness and toughness required for long life. After heat treat, the real magic happens on our CNC grinders: these machines expertly form each tooth of the broach, from the coarse first tooth to the fine finishing teeth at the end. The result is a tool that is as close to perfect as technology allows – often holding tolerances within a few microns on critical features. By keeping the entire manufacturing process in-house, we maintain complete quality control and can accelerate delivery times. Our craftsmen and machines work hand-in-hand to deliver tools that perform right out of the box.

• Coating & Surface Treatments: Depending on your application, we may recommend specialty coatings or surface treatments to enhance tool performance. We coordinate advanced coatings for broach tools (like TiN, TiAlN, or diamond coatings) that can dramatically improve wear resistance when cutting abrasive materials or running high volumes. We also handle surface polishing or oil grooves on broaches if needed to improve chip flow. These finishing touches are all done with careful attention to detail, so your tool not only cuts great on day one, but continues to excel over a long service life.

• Turn-Key Tooling Solutions: As part of our holistic approach, we can deliver turn-key broaching solutions that include the tool, the fixture, and integration guidance for your broaching machine. If you’re launching a new broaching operation, we’ll ensure you have the proper holders, fixtures, and pullers for your broach tool, all dialed in and ready to go. We want your new tool to hit the ground running, seamlessly fitting into your production line. Our team can even assist with initial setup and trial runs to fine-tune the process. It’s all about removing roadblocks so you start reaping the benefits of your custom broach tool from day one.

• Field Service Support & Consultation: Our relationship with customers doesn’t end after delivery. We stand by our tools with ongoing support. If you encounter an unexpected challenge – maybe a material change, a machine issue, or a new part variation – our experts are just a phone call away. We can often diagnose tooling or process issues remotely, or dispatch an engineer to your site if needed. This on-site troubleshooting capability is something that sets U.S. Broach Tool apart as a manufacturer: we care that our tool is delivering value in your real-world production environment. We also offer training for your operators on broach tool handling and maintenance best practices, helping you get the maximum life and performance from each tool. When you choose U.S. Broach, you gain a partner committed to your success, not just a supplier.

• Resharpening, Reconditioning & Repair: Every broach tool will eventually dull with heavy use – but that’s not the end of its life. Our broach tool reconditioning services give your tooling a second (and third, and fourth…) life. We provide scheduled resharpening that restores the cutting edges and geometry of your broaches to like-new condition. With our CNC grinders, we can regrind and re-hone teeth with incredible consistency, ensuring that after reconditioning, your tool performs as good as new. Typical turnaround for sharpening is just three days, so you won’t skip a beat in production. For emergencies, we offer rush overnight sharpening – ship us your worn tool in the evening, and we’ll ship it back the next day sharpened and ready. Additionally, if a broach tool gets chipped or damaged, we can assess and perform repairs or suggest modifications. This extends your investment and reduces long-term tooling costs. Many of our customers set up regular maintenance cycles: by rotating two sets of broaches (one in use, one being sharpened), they keep production continuous. We manage the logistics and tracking of your tools’ service life if needed, effectively acting as your tooling maintenance department.

By offering end-to-end services – design, manufacturing, and ongoing support – U.S. Broach Tool ensures you have a true partner in productivity. We don’t succeed unless you do, so we’ve built our capabilities around maximizing your uptime, quality, and ROI. Few broach manufacturers offer this level of comprehensive support, and it’s one of the reasons our clients stay with us for the long term.

Broaching Machine & Tooling Integration

A broach tool is only as good as the machine that drives it, and vice versa. If you’re in the market for new broaching equipment, want to upgrade your existing setup or used machinery, our team can guide you toward the perfect machine to pair with your tooling. We design our tools to fit seamlessly with your broaching machine – considering factors like stroke length, tonnage, fixturing, and chip evacuation from the start. This synergy between tool and machine maximizes performance, extends tool life, and enhances safety.

From vertical and horizontal broach machines to turnkey automated systems, we’ve got the hardware side covered. Customers get a one-stop solution that is truly optimized from cutting edge to motor. Many of our clients take advantage of this one-two punch – they consult with us on both tooling and machinery to ensure perfect compatibility and peak efficiency.

Remember, a broach machine without the right tool is like a sports car on bad tires – it just won’t perform to its potential. With U.S. Broach, you get both sides of the equation working in concert. If you’re not sure whether your current machine is ideal for a new broaching task, or you’re considering upgrading, let us know. We’ll offer honest guidance, even coordinating with our machine-building colleagues to propose the best path forward for your production goals.

Request a Quote & Consultation

Ready to elevate your manufacturing with the power of custom broach tooling?

• Request a Quote: Already have a specific tool in mind or a print ready for quoting? Just tell us a bit about your needs – part material, dimensions, desired profile, volume – and our team will promptly provide a competitive quote. We pride ourselves on transparent pricing and value, so you can expect a fair price for top-tier quality. No project is too large, too small, or too complex. Whether you need one prototype broach or a fleet of production tools, we’ll give it the attention it deserves.

• Free Consultation: Not sure where to start or facing a broaching challenge? Reach out for a free consultation. Our experts are happy to discuss your application, troubleshoot issues, or brainstorm a solution even before any formal project kicks off. We can often suggest ways to improve part design for broaching, estimate feasibility, or outline what a turnkey broaching solution might look like for you – all at no obligation. It’s part of how we build relationships and prove our commitment to your success upfront.

Expect timely responses, clear communication, and a team that genuinely wants to help you succeed. We know that investing in specialty broach tooling can feel like a big step – our goal is to make the process smooth and confidence-inspiring.

Put us to the test. Reach out today to discover how U.S. Broach Tool can transform your manufacturing process with precision broach tools tailored exactly to your needs. From dramatically reducing cycle times to achieving geometries you once thought impossible, our custom broach tooling solutions are ready to deliver.