The prototype aims to see exactly how your product appears and acts in a real-world scenario. There are different prototyping processes in the manufacturing industry, ranging from CNC machining to 3D printing. The beauty of these processes is their speed and cost-friendliness, as most of them enable you to produce prototypes cheaply. Rapid tooling is another process used for producing prototypes.
Want more information on Rapid Tooling For Electronics? Feel free to contact us.
Unlike the other prototyping processes, this process applied in low volume injection molding helps manufacturers produce tools and project parts cheaply and fast. Prototyping using this approach can help show how different parts of your product would work.
Keep reading as we provide great insight into rapid tooling, what it is, the processes involved, how to make rapid tools, and its benefits and limitations.
Also known as bridge tooling or prototype tooling, this is one of the steps in product development. It involves hand-load inserts, stocked mold base, and mold material. The mold material could be either aluminum or soft steel.
It is a rapid tool that enables you to get project parts cheaply and fast. The result is the production of parts through low-volume injection molding that functions as tools. Manufacturers subscribe to rapid tools because they enable manufacturers to notice and correct flaws in the current design to prevent issues in the final parts before a full-scale investment in production tooling.
Moreover, it allows you to use the same materials for actual production. In order words, they enable you to decide if you have made the right material choices, as you get a clearer picture of your prototype, including how its different parts would function in a real-world scenario. Therefore, using rapid tooling is a good way to develop small-batch orders in process design, marketing, and product evaluation.
With the rise in demand for cheap tooling solutions, there is also a rise in the number of methods used for making rapid prototype tooling. Generally, there are two main methods of making rapid molds. These include:
The direct approach to rapid tooling produces the cavity mold inserts and actual core. One of the major strengths of this approach is its ability to produce tools with geometries that might be unattainable without them. For instance, in the conformal cooling technique, heat removal from the mold is uniform, reducing cooling times by about 66%. This occurs because the internal cooling channels follow the contour present in the mold cavities.
The indirect approach uses master patterns produced through additive manufacturing to make die or mold. While many methods are available for achieving this, soft tooling techniques are commonly used.
Soft tooling involves making use of silicone molds for plastic parts. Furthermore, these silicone molds also serve as sacrificial models when you want to cast metal parts.
Having examined both methods, their merits, and their demerits, how do you choose the ideal one when you want to make a rapid mold? Below are some guidelines you should consider before making your decision.
When making prototyping molds, below are some factors you must consider.
Rapid tooling now has a wide rate of adoption among manufacturers because of the benefits it affords them. Still undecided on whether to use it for your prototyping needs? Here are some benefits rapid production tooling affords you.
Materials used in making a rapid mold are often cheaper and more flexible than those required for making a conventional mold. These materials range from different types of aluminum to steel.
Besides, 3D printed tooling being cost-effective helps you save money spent on production because the faster the process, the less you spend.
If you want to learn more, please visit our website high volume cnc machining service.
It results in faster production of both prototypes and products. Besides, this speed reduces the time spent in the prototyping stage of production, hastening the time to market.
With this prototype tooling, you can create your custom mold with any dimension. You can also run different materials through the mold and perform quality control tests on them. This comes in handy when you are unsure of the ideal material for your product.
This prototyping method gives you the leverage to make several prototypes or molds in a short time, sometimes in hours. It also gives you the freedom to test out new ideas and adjust old ones. This, in turn, helps improve design functionality and market value.
Another advantage is that it hastens product development time, which in turn ensures you start recouping your investments in a short time. Also, lower production and prototyping costs reduce the time spent getting your ROI because you incur fewer expenses.
Its possible to produce rapid molds or tools in the shortest time, which accelerates the production of plastic parts. However, there are still limitations to rapid tooling. Below are a few of them.
Prototyping with rapid tooling is a repetitive process, and this means spending more on injections, especially if you are looking to perfect a design. Higher injection costs translate to higher labor costs, which could increase your cost of production.
Rapid molds do not last long. This is due to the stress placed on them by the injection process. Besides, the materials used in producing the molds like aluminum and steel, are not of high quality. Hence, you would end up creating a new mold from time to time, as the previous ones wear out.
Some people feel rapid tooling and rapid prototyping are the same, which is not true. There are differences, and we will discuss them here.
Rapid tooling involves the production of a tool or mold that enables manufacturers to rapidly-produce parts of a product that would function as a tool. Furthermore, there are two approaches to prototyping here; direct method and indirect method. But the common technique used is injection molding.
On the other hand, rapid prototyping is a technology or method that aids the rapid production of a physical part for end-use or use as a prototype. In addition, the common technologies involved in rapid prototyping are additive manufacturing (3D printing) and subtractive manufacturing (CNC machining).
Want to realize your plastic products from a design in the shortest possible time? That is exactly what rapid tooling does for you.
Thankfully, RapidDirect remains the go-to company for your rapid tooling needs. Our top-quality injection molding service includes rapid tooling services. We tailor our services to meet clients demands, ensuring the production of quality prototypes. Furthermore, you do not have to break your bank to get a prototype of your design, as we offer one of the best prices in the industry.
Not sure what producing your design would cost? RapidDirect offers you an online quotation platform. All you need to do to access the quotation is upload a design file.
Try RapidDirect Now!
All information and uploads are secure and confidential.
There are many benefits rapid tooling provides manufacturers, from saving time to reducing costs. We believe with the above information, you have gotten great insight into the different methods involved in this process and what differentiates it from rapid prototyping.
Irrespective of the type of product you want to develop, you must hire a reputable prototype manufacturer. With several manufacturers in the market, RapidDirect is the recommended manufacturer for all your prototyping needs.
In the broadest sense, rapid tooling is any method or technology that enables you to produce tooling quickly. Many business agree, however, that it means tooling driven by an additive manufacturing (AM) process is the key to making it rapid.
DirectSteel injection mold and molded parts, courtesy of EOS
Two categories of rapid tooling have developed. One is an indirect approach that uses one or more master patterns to produce a tool. An example is epoxy-based composite tooling.
The second category is a direct approach, meaning that an AM process builds the core and cavity mold inserts directly, in the case of injection mold tooling. Direct metal laser sintering from EOS has been used to produce these types of tools.
If you are looking for more details, kindly visit rapid tooling systems.