Custom Coolant Nozzle for Mazak Integrex I-200 HS Tool Holders
This project focused on redesigning a coolant nozzle system for Mazak Integrex I-200 HS tool holders to solve serviceability and durability problems in the original design. The original nozzle used a black oxide alloy steel body that could corrode over time and become difficult to remove after installation with threadlocker. I developed a replaceable multi-part nozzle system that improved corrosion resistance, reduced maintenance risk, and allowed worn sealing components to be serviced without removing the permanently installed body.
Improving serviceability without risking damage to the tool holder
The main engineering challenge was to improve a component that operated inside a through-spindle coolant system where sealing, corrosion resistance, durability, and serviceability were all critical. The original design created unnecessary maintenance risk because removal of the threaded body could damage the tool holder. The redesign needed to protect the holder, reduce corrosion, and keep the assembly maintainable over time.
A replaceable internal nozzle system
The redesigned assembly uses a threaded body, tubular insert, O-rings, washer, and retaining clip arrangement to maintain sealing and retention while making the assembly serviceable. The threaded body remains installed inside the tool holder, while the replaceable internal components can be changed without risking damage to the holder itself. This also helps prevent spindle flooding in through-spindle coolant operation, reducing the chance of bearing or sealing damage caused by coolant leakage.
Measurement, CAD recreation, and machining
I measured the original geometry and critical features using a contour measuring device, comparator, caliper, and pitch micrometer. After documenting the functional geometry, I recreated the design in SolidWorks, assembled the components digitally, and then machined the parts myself. Manufacturing included turning the cylindrical components and milling the slot in the threaded body.
Improved corrosion resistance in the installed threaded body.
Improved durability and wear resistance in the replaceable tube component.
Sealing components can be renewed without removing the installed body.
Allows service without risking damage to the tool holder.
Selected project visuals
Use 6 strong images here. Mix actual machined parts, CAD part images, and one assembled view so the gallery feels technical, clear, and professional without getting crowded.
This project is one of the best examples of how I approach engineering: identify a failure point, understand the real operating environment, redesign for function and serviceability, then make the part and verify that the idea works in practice.
