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Milling operations are commonly characterized by high energy consumptions and should be in focus for optimizations aiming at sustainable manufacturing processes. Research results show that within milling operations, especially in SME, up to 80 % of the applied milling cutters are solid end mills. The paper provides a proposal for a reference part which will allow a standardized evaluation of the energy efficiency and technical capability of solid end mills based on facts taken directly from the field of application. Therefore ten representative parts were selected from a portfolio of more than 1.000 parts out of five companies from different industry sectors. These ten parts were analytically examined regarding their geometrical features and their applied machining modes for a subsequent split up into more than 250 different weighted single components and measures. Based on a scientific recomposition of these single components and measures the reference part was developed.

Driven by the high importance of resource efficiency the importance of lightweight construction rises across all industries. Due to their high lightweight construction potential, carbon fiber reinforced plastics (CFRP) are increasingly applied. But CFRP manufacturing often is an expensive small-scale production where it is necessary to use removable mold cores to manufacture hollow parts. To improve the complex process of mold core making future process chains including additive manufacturing (i.e. 3D-printing) can be used. This paper provides a proposal for a hollow CFRP reference part based on facts taken directly from the field of application. The reference part will allow the evaluation of economic and ecological impact of process chains in mold core making for the CFRP production. Therefore, representative parts from different industry sectors were selected and analytically examined regarding their geometrical features. Based on a scientific recomposition of these features the reference part was developed.