Mastercut Tool Uses DTO Inkjet Solutions to Optimize Production for More Than 20,000 SKUs

The XD70 single-pass platform. | Credit: EPS

Engineered Printing Solutions (EPS) has enabled Mastercut Tool to build a scalable, cost-focused decoration strategy for its industrial tooling packaging, using a combination of multi-pass and single-pass direct-to-object (DTO) inkjet technologies to optimize production across tens of thousands of part numbers.

Mastercut Tool, a U.S. manufacturer of precision carbide cutting tools including end mills, drills and burrs, ships every product in a rigid plastic case that carries unique identification, technical data and regulatory markings. With no shared artwork across products, the company required a decoration process that could handle constant change without introducing cost or production inefficiency.

Traditional approaches such as pressure-sensitive labels, pad printing and screen printing proved difficult to scale. Traditional labels introduced ongoing material and labor costs alongside durability challenges in harsh environments, while analog print processes required SKU-specific tooling, creating a level of setup complexity that was not viable for a catalog of this size.

Working with Mastercut for more than a decade, EPS helped the business transition to a two-tier DTO inkjet production model. The solution combines multiple Fjet multi-pass systems for short and mid-run production with an XD70 single-pass platform enabling high-volume output.

Mastercut can route each job based on run length and cost per unit. The multi-pass systems provide flexibility for frequent changeovers across the long tail of SKUs, while single-pass delivers the throughput needed for continuous production runs. A shared digital artwork workflow supports both platforms, removing the need for tooling and ensuring consistent output across the entire range.

As a result, Mastercut has eliminated label-related costs, reduced inventory and rework, and aligned its decoration process with ongoing catalog expansion. New SKUs can be introduced through simple artwork updates, all without disrupting production or requiring additional setup.

“We carry tens of thousands of active SKUs, and every one of them needs its own part number, description, and warning on the case,” said Michael Shaluly President and CEO of Mastercut Tool Corp. “There is no analog process on earth that makes that math work. Pad and screen would need a new tool for every SKU—that is not a packaging program, that is a museum of clichés. Direct-to-object inkjet is not a nice-to-have for us. Without it, this catalog does not ship.”

The company also highlighted the flexibility of combining inkjet technologies. “Some SKUs run in small batches while others run continuously. With multi-pass and single-pass running side by side, we can match each job to the most cost-effective process”

Ken Stack, Executive Chairman at EPS, said the work reflects a practical approach to working with customers and applying digital inkjet printing as a part of the overall manufacturing process. “This is about cost engineering, not technology replacement,” he said. “Mastercut runs multi-pass and single-pass DTO together, so each job lands on the right platform. That is what allows businesses such as Mastercut to control cost across a very complex SKU mix.”

EPS works with manufacturers to manage multiple SKU counts, helping them evaluate where digital inkjet can improve cost, simplify workflows and scale production.

Source: EPS