The Basics of Rapid Tooling

Rapid Tooling is the result of combination of rapid prototyping techniques and coventional tooling practices to create a cost effect and quick mold.Rapid tooling-feature image

Rapid tooling is a considerably new manufacturing process that has been developed when small batch customized parts became widespread. The demand for such parts established flexible technological processes, where manufacturing preparation must be as short as possible, so tooling production had to be shortened.

A Short Overview of the Conventional Tooling Methods

The manufacturing process of conventional tooling is quite similar to the manufacturing of low-batch commercial parts. Depending on the technical requirements, a blank is either cast, forged or just bought (chosen as a cylinder from the standard diameter list). It is then machined, heat-treated to increase its durability and then ground and finished using precision manufacturing techniques.

Overall, depending on the complexity and the number of parts, manufacturing, take a plastic injection mold, for example, requires months. Therefore, sometimes it is better to use less time and manufacture the tooling with worse properties, however, that those are enough to make a prototype or a test-batch of the product.

Rapid Tooling Today

RT technologies are currently developing from a scientific concept into a commercial industry. The RT processes are currently used by the frontline prototyping companies to further decrease the lead-time of the product. The difficulty in tooling manufacturing is in combining the multitude of manufacturing techniques with the design possibilities they enable and part properties they provide. Due to a lack of research in the RT processes, repeatability is also a big issue that has to be assessed yet.

RT Methods

Despite the novelty of rapid tooling, a significant number of rapid manufacturing techniques exist nowadays. A lot of them have descended from the rapid prototyping technologies, however, with some changes. The precision and durability requirements towards tooling are much higher than for simple prototypes. So, here is a list of the most significant RT techniques.

CNC Machining

Rapid tooling-2

CNC machining is the most conventional of RT techniques. The development of CNC systems has made the machining processes much more flexible and lead time much shorter. The need for specialized fixtures is gone since the probes can determine the exact position and dimensions of the blank.

Any kind of surface can be manufactured with a very tight tolerance (up to a few microns) on the 5-Axis machine tools.  Rapid machining services make it possible to order a prototype or a small batch without the need to invest in expensive equipment.

Overall, this method is one of the best in terms of precision and available material range. CNC parts, however, have some limitations when it comes to cavities.  It is hard to manufacture sharp edges and deep grooves.

3D Printing

Rapid tooling-3

Additive manufacturing is one of the newest processes that found its use among the RT techniques. There are different additive processes but the most widely used ones for tooling are bed fusion and direct metal deposition. Both of them use metal powder sintered together layer-by-layer to obtain the desired part.

The main advantage of 3D printing is its unprecedented flexibility. You need no fixtures at all and you do not require blanks. The metal powder is universal. You can also create sharp corners and cooling channels that are impossible to make using other processes. The downside of the process is that the surface quality is not very good, so you will have to spend some time post-processing.

Soft Silicone tooling

Rapid tooling-4

When manufacturing plastic prototypes or low-volume batches, producing conventional injection molds is too long and expensive. So, soft tooling is manufactured instead. The process requires a master-model that has to be manufactured either manually (wood will do) or by 3D-printing or CNC prototype machining. The master part is suspended over the tank and liquefied silicone is poured over it. Once the silicone hardens, it is cut in half and the master model is ejected. The result is an injection mold made of silicone that can withstand up to 15 uses.

EDM Tooling

Rapid tooling-5

Electrical Discharge Machining is indispensable when your tooling has to be made of very hard material. For example, some dies that are used to manufacture titanium alloy parts withstand tremendous stresses even when prototypes are manufactured. So, instead of spending a ton of time cutting small chips off the blank using a milling center, it is more preferable to make a reversed cavity form on a softer material (aluminum or copper) and install it as a tool on an EDM machine.

EDM employs electrical discharges between the blank (the future titanium dies) and the tool (copper with the reversed cavity). Small titanium particles are evaporated due to the discharges and the tool is lowered thus creating the cavity in the titanium much faster.

Advantages of Rapid Tooling

Using intermediate tooling to produce a small quantity of prototypes or functional tests is a key process to the product development cycle. Rapid tooling plays great role during marketing samples, evaluation purposes, and production process design.

  • Satisfy Custom mold for personal applications
  • Flexible rapid tooling materials selection is decided by the client and followed by cooperative partner
  • Fast prototyping product can be launched into the market than the predicted time
  • Compared with the products are manufactured by mass-production injection tools,
  • the price of products can be cheaper
  • Shorter tooling time, cheaper tooling time than conventional tool
  • Get rid of troubleshooting existing problems
  • Obvious time advantages on shorting product lifecycle, lowering the cost and the time of product manufacture while creating molds for various commercial operations
  • Strong ability to manufacture wide range of injection molding materials till create perfect custom molded products

Which Type of  Rapid Tooling is Right for Your Product

We all know that creating a mold with rapid tooling is not always helping to save lots of time. When it comes to mold manufacturing, rapid tooling is typically faster than traditional machining of steel or aluminum, but the process of  finishing touches that maybe can slow your process down once the mold is shaped or created.

If you have any questions about creating low volume molded plastic parts.

The Future of Rapid Tooling

The RT processes are very promising in the current era of customized goods. That is why a lot of companies invest in research that concerns itself with inventing new ways to rapidly manufacture tooling.Existing processes are being constantly improved as well. Only a few years ago we couldn’t dream of using printed parts for anything rather than models but now, functional printed parts are used in a wide range of different machines.

CNC precision, materials and speeds are being improved as well. New cutting speeds are reached every year and the improvements are only growing at a rapid rate.

Same things can be said for soft tooling Silicone molds are being cured in the oven now to increase their durability. New plastics are being constantly developed.

RT will soon move from prototypes and single parts into full-scale mass production.

Under the Influency of Trade War

During the trade disputes, the united states unreasonably imposes heavy taxes on machining industry. As we know, since the mold industry can be regardes as “the mother of manufacturing”, it must be a heavy strike for us to rely on the advantages of price in an old way. On the contrary, trade dispute is a good news for America that exports high quality moulds with high precision and high-tech, they can eaily defeat us on price reasons while not influced more under our revenges.

Although China’s mold industry takes leads in yeilds and exports, but whatever it refers to the level of design and making is much lower than America, we can take for the lifetime of molds as an example. It suggested that domestic mold companies take proactive polices to industry upgrading while abanding the old teeth of price advantages.

Where Should Injection Molding Industry go Tomorrow?

1.Lift improvement to the mold industry techniques.With coming up with Made in China 2025, more and more companies have passed quality system certification so as to embrace new situation.Besides, these companies combine CAD/CAE/CAM & 3D techiniques with ERP & IM3, some revolutionary cool-tech include High speed machining, rapid prototyping,visual simulation,robotics and smart manufacturing have been applied to mold maching industry.

2.Optimize scale of mold machining bases.With the increasing demands from domestic and abroad, tradtional mold workshops must improve the modes of managements towards larger direction.In recent years, Mold city, Mold park, Mold production bases etc have rapidly spread in the whole national, thus creating the strinking scale of economy and industrial clusters.

3.Attach great importance to Brand and Patent and strengthen innovation and research and development.With the development market-economy, some entreprenuial enterprises and star-ups have come to realize their importance of innovation and R&D and input more investment, because they think brand and pattern have become the development trend of molding industry in the future.

4.Provide more Support for mold industry personnel trainings.In recent years,although staffs are increasing employed by China’s molding industry, we still cannot catch up with the requirements of industry for which lacking for related enterprised managers, middle and senior techinical personnels with high quailty. So, quality and numbers of talents will be our persuit.

Wayken Should do

When it comes to Rapid Production Tooling, WayKen specializes in rapid tooling of both aluminum and steel and low volume plastic injection molding to turn over your specific material parts within 2-5 weeks while exceeding  your highest expectations.Faced with the risk of trade dispute, we still have a long way to go in presicion, lifetime, manufacturability of mold compared with the advanced industrial nation. Reducing imports and strengthening manufacturiabilty will be our ultimate goal in rapid injection molding industry.

58 thoughts on “The Basics of Rapid Tooling”

  1. Hello there, I found your blog by way of Google at the same
    time as searching for a related subject, your website got here up, it seems to be great.
    I’ve bookmarked it in my google bookmarks.
    Hi there, just become alert to your blog through Google,
    and located that it’s really informative. I’m gonna be
    careful for brussels. I’ll be grateful should
    you proceed this in future. A lot of other people might be benefited
    from your writing. Cheers!

  2. Hey there would you mind stating which blog platform
    you’re using? I’m planning to start my own blog in the
    near future but I’m having a hard time making a decision between BlogEngine/Wordpress/B2evolution and
    Drupal. The reason I ask is because your layout
    seems different then most blogs and I’m looking
    for something completely unique.
    P.S My apologies for being off-topic but I had to ask!

  3. Hi there, just became aware of your blog through Google,
    and found that it’s truly informative. I am gonna watch out for brussels.

    I will be grateful if you continue this in future. Many
    people will be benefited from your writing. Cheers!

  4. Great blog! Is your theme custom made orr did you downlosd it from
    somewhere? A heme like yours with a feew simple adjustements would really make
    my blog stand out. Please let me know wheere you got your design. Appreciate it
    kamagra online apotheke web site
    Genedrika ohne Rezept

  5. Учение мониторинга подвижных объектов, построенная на Предсказывать землетрясения предложили по смартфонам основе систем спутниковой навигации, оборудования и технологий сотовой и/или радиосвязи, вычислительной техники и цифровых карт. Спутниковый мониторинг транспорта используется чтобы решения задач транспортной логистики в системах управления перевозками и автоматизированных системах управления автопарком.

  6. Pretty nice post. I just stumbled upon your weblog and wanted to say that I have really enjoyed
    browsing your blog posts. In any case I will be subscribing to your rss feed and I hope you write again very soon!

  7. Hmm is anyone else experiencing problems with the
    pictures on this blog loading? I’m trying
    to figure out if its a problem on my end or if it’s the blog.

    Any feed-back would be greatly appreciated.

  8. We are a group of volunteers and starting a new scheme in our community.
    Your web site provided us with valuable information to work on. You have done an impressive job and
    our whole community will be thankful to you.

  9. I always used to read post in news papers but now as I am a user of web thus from now I am using net for posts,
    thanks to web.

  10. Hi, i read your blog occasionally and i own a similar one and i was just curious if you get a lot of spam responses?
    If so how do you prevent it, any plugin or anything you can recommend?
    I get so much lately it’s driving me mad so any support is
    very much appreciated.

  11. I’ve learn some excellent stuff here. Certainly value bookmarking for
    revisiting. I surprise how a lot attempt you set to create any
    such fantastic informative site.

  12. With havin so much content do you ever run into any problems of plagorism or copyright infringement?
    My site has a lot of unique content I’ve either created myself or outsourced but it looks like a
    lot of it is popping it up all over the web without my permission. Do you know any techniques to help protect against content
    from being stolen? I’d certainly appreciate it.

  13. I do not even know the way I finished up here, however I thought this submit was once great.
    I do not recognize who you’re but certainly you’re going to a famous blogger if you happen to aren’t already.

  14. This is really interesting, You’re a very skilled blogger.
    I have joined your feed and look forward to seeking more of your fantastic post.

    Also, I have shared your site in my social networks!

  15. What’s up all, here every one is sharing these kinds of experience,
    thus it’s pleasant to read this weblog, and I used to visit this webpage everyday.

  16. Fantastic beat ! I would like to apprentice whilst you amend
    your site, how could i subscribe for a blog website?
    The account helped me a appropriate deal. I have been a little bit acquainted
    of this your broadcast provided shiny clear concept

  17. Good day I am so glad I found your site, I really found you by accident, while I
    was looking on Aol for something else, Nonetheless I am here now and would just like to say thanks a lot for a incredible post and a all round
    enjoyable blog (I also love the theme/design), I don’t
    have time to read it all at the minute but I have book-marked it
    and also added in your RSS feeds, so when I have time I will be back to read a
    great deal more, Please do keep up the great work.

  18. What’s up it’s me, I am also visiting this website regularly,
    this website is really fastidious and the viewers are actually sharing fastidious thoughts.

  19. Hey There. I found your weblog the use of msn. This is
    an extremely well written article. I’ll make sure to bookmark it and return to learn more of
    your useful information. Thanks for the post. I will certainly comeback.

  20. Oh my goodness! Impressive article dude! Many thanks, However I
    am having difficulties with your RSS. I
    don’t understand the reason why I can’t subscribe to it.
    Is there anyone else having the same RSS problems?
    Anyone that knows the solution can you kindly respond?

  21. After I originally commented I seem to have clicked the -Notify me
    when new comments are added- checkbox and now every time a comment is
    added I receive 4 emails with the same comment.
    Perhaps there is an easy method you can remove me from that service?

  22. We’re a group of volunteers and starting a new scheme in our community.
    Your website offered us with valuable information to work on. You’ve done
    an impressive job and our whole community will be grateful to you.

  23. Do you have a spam issue on this website; I also am a blogger, and I was curious about your situation; we have created some nice procedures and
    we are looking to trade methods with other folks, please shoot me an email if interested.

  24. Hey! Someone in my Facebook group shared this site with us so I came to give it a look.
    I’m definitely loving the information. I’m book-marking and will
    be tweeting this to my followers! Exceptional blog and brilliant design.

  25. В нашем ассортименте весьма много инструментов, применяем парсеры-специализированные приложения с целью накопления данных
    и далее преобразования их в организованный формат записи,
    в основном работают с типами текстовой
    и графической информации.
    Парсеры разбирают информацию очень быстро,
    распознавая огромные характеристики
    систематически обновляемых параметров и
    находя правильные данные для вас.
    Синтактический анализ используется,
    если требуется немедленная и эффективная переработка данных.
    Парсинг-это постоянная синтаксическая оценка
    информации, размещенных на интернет-сайтах,
    какие используются для быстрой и эффективной обработки немалого числа информации.
    Затем чтобы эффективно продвигать веб-сайт,
    вам нужно немало тщательно собранного контента, нужного для вашей основной аудитории, который
    легко и недолго создавать вручную, и вы
    не можете обойтись без парсера
    здесь если говорят номер занят оставьте сообщение на автоответчик.

  26. Hi! I know this is kinda off topic but I was wondering which blog platform are you using
    for this site? I’m getting sick and tired of WordPress because I’ve had issues with hackers and I’m looking at alternatives for another platform.
    I would be awesome if you could point me in the
    direction of a good platform.

  27. A person essentially help to make critically posts I’d state.
    This is the first time I frequented your website page and
    so far? I surprised with the research you made to create this actual publish
    incredible. Excellent activity!

  28. You really make it seem so easy with your presentation but I find this topic to be really something which I think I
    would never understand. It seems too complex and very broad for me.
    I am looking forward for your next post, I will try to get the hang of it!

  29. Have you ever thought about writing an ebook or guest authoring on other sites?
    I have a blog based upon on the same topics you discuss and
    would really like to have you share some stories/information. I know my visitors would enjoy your work.
    If you’re even remotely interested, feel free to shoot me an e-mail.

  30. Thanks for one’s marvelous posting! I really enjoyed reading it, you might be a great author.I will remember
    to bookmark your blog and will often come back later on.
    I want to encourage yourself to continue your great job,
    have a nice evening!

  31. Howdy! This is kind of off topic but I need some advice from
    an established blog. Is it hard to set up your own blog?
    I’m not very techincal but I can figure things out pretty fast.
    I’m thinking about setting up my own but I’m not sure where to begin. Do you
    have any ideas or suggestions? Thank you

  32. Hey there! Quick question that’s completely off topic.
    Do you know how to make your site mobile friendly? My site looks weird when viewing from my iphone.

    I’m trying to find a theme or plugin that might be able to resolve this
    issue. If you have any suggestions, please share.

  33. Write more, thats all I have to say. Literally, it seems
    as though you relied on the video to make your point.
    You obviously know what youre talking about, why waste your intelligence on just posting videos to your site when you could
    be giving us something enlightening to read?

Leave a Reply to เว็บเล่นหวย Cancel reply

Your email address will not be published. Required fields are marked *