Sonic Tools

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Sonic Tools Designing, Engineering, & Manufacturing precision cutting tools for 20+ years. We make the hard stuff, tools others have said are impossible.

We are American manufacturing. Sonic Tools LP builds solid carbide end mills and custom carbide tooling in Ashland, Virginia. Sonic prides it's engineering solutions for solving problems around the constraints of the job, rather than being adapted from what already exists. We're trusted when the geometry doesn't exist in any catalog, or the tolerance a previous supplier said couldn't be met still needs to be, or when worn tools need end mill reconditioning to the same spec as new tooling. We solve the problems that others can't. Standard catalog and fully custom, on 5-axis CNC grinding machines, with engineering and production under the same roof. Aerospace, firearms, biomedical, power generation and more. Manufacturing tooling solutions in the USA since 2004

Nine flutes give you a choice.For a finer finish, nine edges can share the feed you already run. For a shorter cycle, th...
10/15/2026

Nine flutes give you a choice.

For a finer finish, nine edges can share the feed you already run. For a shorter cycle, they can carry a faster table at the same chip load.

190 Series, the most flutes on any end mill we make.

Learn more: https://tr.ee/qvxsjS

What flute count are you finishing hard steel with now?

One dovetail cut can go by three angles. In a catalog that lists the angle per side, our 30° cutter would be a 15°. Your...
10/15/2026

One dovetail cut can go by three angles. In a catalog that lists the angle per side, our 30° cutter would be a 15°. Your print may call the same cut a 75° wall. We list ours by the included angle.

Our site lists every 931 size, so you can check the cutting length against your depth too: https://tr.ee/WzIs4m

Does your print give you the wall angle or the included angle?

Extra flute length costs you stiffness.The 1/2" 200 Series answers that with six cutting lengths, from 0.5" to 3", so yo...
10/08/2026

Extra flute length costs you stiffness.

The 1/2" 200 Series answers that with six cutting lengths, from 0.5" to 3", so you only run as much flute as the wall needs.

Every length is balanced to reduce chatter, and its polished flutes and TiB2 coating limit built-up edge in aluminum.

Find your length here: https://tr.ee/h5bmme

The tool's print gives the reach. The part print shows us why. Giving our engineers the full picture fills in the contex...
09/29/2026

The tool's print gives the reach. The part print shows us why.

Giving our engineers the full picture fills in the context required to create the optimal tool for the job. Connecting the build to the application bridges the gap between an ask and a purpose.

The part tells the tool how long is long enough. Building the context builds the design.

Can't share the whole print? Send us the feature you're cutting. Our engineers can take it from there.

https://tr.ee/JRPoPl to learn more.

Is a chamfer always 45°? Five 910 angles say no.Your print calls out 20° on a 4140 housing. That's the 20° AlTiN 910. Cu...
09/15/2026

Is a chamfer always 45°? Five 910 angles say no.

Your print calls out 20° on a 4140 housing. That's the 20° AlTiN 910. Cut the same housing in 6061 and it's the TiB2 option. Either way, you chamfer it in the setup you milled it in.

When it isn't 45°, tell us what it is and we'll tell you the part number.

https://tr.ee/b4ZGWs to get started.

What do you need from your corner rounding cutter? Strength, or room to get into the corner?That's a trade every job mak...
09/13/2026

What do you need from your corner rounding cutter? Strength, or room to get into the corner?

That's a trade every job makes differently. On one shank, a bigger radius means a smaller pilot.

A bigger pilot is a stronger tool. A smaller pilot fits a tighter corner.

The print picks your radius. The pilot comes with it. Worth knowing which you need before you order.

https://tr.ee/kL1rTR if you want to see options.

The scorecard wasn't worth posting, but the day was.Sonic Tools signed on as a Platinum Sponsor of the First Annual Kosm...
09/09/2026

The scorecard wasn't worth posting, but the day was.

Sonic Tools signed on as a Platinum Sponsor of the First Annual Kosmo Machine Charity Golf Tournament, and Kosmo ran it right.

Thanks to their team for putting it together, and to every sponsor and player who turned out to support a good cause. Organizing a field like that on one course isn't easy to pull off.

Same time next year?
...

When the tolerance is tight, close enough doesn't cut it.Our solid carbide 970 keyseat line runs 25 width and diameter c...
09/03/2026

When the tolerance is tight, close enough doesn't cut it.

Our solid carbide 970 keyseat line runs 25 width and diameter combinations across six cutting diameters, with widths from 1/64" to 1/4". That means nothing if the job calls for something else.

When the print doesn't match the catalog, our engineers are a phone call away. We like the jobs that don't have an easy answer, so if standard line tools don't fit, let's find what does.

What tricky geometry is in front of you? Send us the print.

https://tr.ee/1lGgM8

You've ordered the custom tools for the job and you gave your customer the delivery date. Can you guarantee it if you do...
09/01/2026

You've ordered the custom tools for the job and you gave your customer the delivery date. Can you guarantee it if you don't have all of the details?

If you're making promises based on estimates, every date you set behind it is an estimate too. The job on the floor gets scheduled regardless.

Transparency is the baseline when you order custom tooling from Sonic Tools. Our customs are ground in-house in Ashland, VA, and the engineers who spec them answer you directly. Full disclosure.

Tell us what you need quoted and when you need it: https://tr.ee/uGtY5s

These two tools started exactly the same but tell very different stories. In a few more steps of our reconditioning proc...
08/26/2026

These two tools started exactly the same but tell very different stories.

In a few more steps of our reconditioning process, the reground tool will pick up right where it left off.

Get more value out of what you already have. We'll handle the tools you can't keep in rotation.

How many regrinds do you typically get out of your tools before scrapping them?

Address

10455 Dow Gil Road
Ashland, VA
23005

Opening Hours

Monday 8am - 5pm
Tuesday 8am - 5pm
Wednesday 8am - 5pm
Thursday 8am - 5pm
Friday 8am - 5pm

Telephone

+18047980538

Website

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