A process for fabricating a cross rolling die is disclosed. A flat wooden cross roll tooling model blank cut to the specified die dimensions is milled by a conventional milling machine to produce a pre-form blank in accordance with the desired cross roll die surface. A face cast of the thus contoured wooden model blank, or a negative impression, is then made which, in turn, is used to make a positive cast of the wooden model blank. A series of closely spaced cuts parallel to the axis of roll is then made in the wooden model blank and the positive cast of sufficient depth to provide radial flexibility in each of these pieces. The model blank is then divided into segments for separate mounting on the cross roll die mounting plates, with each segment mounted separately so as to cover approximately 315.degree. of the full 360.degree. displacement of the cross rolling machine. The transverse cuts in the wooden model blank and positive cast are then filled with a hard-setting filler material and the surfaces of the model blank and positive cast are then contoured by grinding down. A sand cast is then made of each segment from which corresponding face casts are made. Abrader die casts are then in turn made of each face cast. A graphite electrode is then abraded on each abrader die and a cross roll die blank is then formed by means of electrical discharge machining (EDM) from which the cross roll die may be formed.