Discover more of Steel Tooling/Rapid Injection Tooling

Welcome to IDEAL's ultimate guide to Discover more of Steel Tooling/Rapid Injection Tooling!
Our blog is a comprehensive resource for anyone interested in learning more about this versatile and affordable option.

What Is Rapid Tooling? 

Rapid tooling is a way to simplify the mould structure for low cost & short lead-time. It's commonly used in the field of rapid injection moulding, based on the low-volume requirement. Ideal Rapid manufactures its own rapid tooling in 7075 rapid aluminium (moulds can be textured) and pre-hardened P20 tool steel, to make the cavity, core and ejector plates. They are then fitted into a Master Unit Die (MUD based system) with standard tooling components, in order to produce Injection Moulding parts.

Rapid Aluminium Tooling vs Conventional Tooling?

Rapid Aluminium Tooling is very suitable or low-volume production prototype runs, providing a cost effective solution with shorter lead-time than traditional production tooling. For Rapid Tooling, we can typically be 30-50% cheaper than full production tooling, with a 40-60% reduction in lead-time compared to traditional moulds.

Typically, we are able to go from initial DFM design through to tooling manufacture, mould flow analysis, and initial samples in approximately 5 to 28 calendar days(depending on product complexity and tool functionality).

Ideal Rapid's professional knowledge and expertise in rapid manufacturing really does cut down a lot of the time & cost of producing your prototype!

What Metal Material Are Used For Rapid Tooling?

Rapid tooling often utilizes various metal materials depending on the specific requirements of the project. Common metals used include:

Aluminum: Lightweight and easy to machine, aluminum is often used for making molds and tooling due to its good thermal conductivity and relatively low cost.

Steel: Tool steels, such as P20, H13, and S7, are frequently used because of their durability and ability to withstand high temperatures and pressure, making them suitable for injection molding applications.

Stainless Steel: Known for its corrosion resistance and strength, stainless steel is sometimes used for tooling that requires long service life and exposure to harsh conditions.

Magnesium Alloys: Lightweight and with good machinability, magnesium alloys can be advantageous for certain rapid tooling applications.

Copper: Often used for its excellent thermal properties, copper is suitable for molds that require precise temperature control.

The choice of material depends on factors such as the type of process (e.g., injection molding, casting), the production volume, and the properties required for the end product.

Advantages of Rapid Tooling

Rapid tooling offers several advantages that make it an appealing choice in product development and manufacturing processes:

Reduced Lead Time: Rapid tooling significantly shortens the time required to develop molds or tools, allowing products to reach the market faster.

Cost Efficiency: For low to medium production volumes, rapid tooling can be more cost-effective than traditional tooling methods, as it reduces initial investment costs.

Flexibility: Rapid tooling allows for quick changes and iterations in design. This is particularly beneficial for prototyping and testing multiple versions of a product.

Improved Design Iteration: Designers can experiment with different designs and make adjustments based on testing and feedback without incurring significant costs or delays.

Enhanced Precision and Quality: Many rapid tooling processes result in high-precision components, ensuring that the final product meets specific tolerances and quality standards.

Material Variety: Rapid tooling can be done using various materials, accommodating diverse requirements for different applications and industries.

Reduced Development Risk: By enabling quicker prototyping and testing, rapid tooling helps identify potential design flaws early in the development process, reducing overall risk.

Better Collaboration: The fast turnaround allows for closer collaboration among design teams, engineers, and manufacturers, leading to improved overall product quality.

These advantages contribute to more efficient manufacturing processes and can lead to better overall product outcomes in terms of performance, quality, and market responsiveness.

Challenges of Rapid Tooling

Rapid tooling, which involves the quick production of tools and molds used in manufacturing, presents several challenges:

Material Limitations: Rapid tooling often utilizes materials that may not match the strength, durability, or heat resistance of traditionally machined tools, limiting their use in high-volume or high-stress applications.

Accuracy and Surface Finish: Achieving the required precision and surface finish can be challenging, particularly with certain rapid tooling techniques. This might necessitate additional finishing processes.

Complexity and Size Limitations: While rapid tooling is excellent for simple or moderately complex geometries, extremely complex designs or very large molds can be difficult or impossible to produce.

Cost-Effectiveness: While rapid tooling can significantly reduce lead times, the initial setup costs for the technology (e.g., 3D printers or CNC machines) can be high, which can offset the benefits for small production runs.

Technological Learning Curve: Implementing rapid tooling technologies requires specialized knowledge and skills, which might involve a learning curve for the workforce.

Integration with Existing Processes: Rapid tooling needs to be compatible with existing manufacturing processes, which can involve challenges in terms of aligning with established workflows.

Design Considerations: Products need to be designed with rapid tooling in mind, which can require changes to existing design paradigms.

Addressing these challenges often involves a combination of selecting the right materials, optimizing designs specifically for the tooling process, and balancing the cost-benefit ratio for each specific application.

Bridge to Production Process

Prototype tooling in 5 to 28 calendar days.

Rapid aluminium tooling for volumes up to 5000+ shots.

P20 prototype tooling for volumes up to 50,000+ shots.

NAK80 or S136 prototype tooling for volumes up to 100,000+ shots.

The Experts In Aluminium Profiles and Extrusions

Ideal Rapid has grown from a sole powdercoating company, today to a major distributor and finisher of an extensive range of rapid aluminium profiles and extrusions for the architectural and commercial building industry. Our head office in Shenzhen China includes our main warehouse and workshop. We think of it as our "beating heart" of aluminium. From here, our service flows to all corners of the world via our regional centres. It's a strange concept but aluminium is our lifeblood and it flows in our veins. We know all there is to know about aluminium shapes, colours and finishes. You can use us as a complete resource for rapid aluminium profiles and extrusions. We design and supply aluminium profiles for all your commercial and partitioning needs. Try the Ideal Rapid difference and benefit from our service and experience.

Are You Ready To Start Your Next Project?

Rapid Tooling plays an important role in several industries, especially in the production of light-usage or the short-run manufacturing of large parts for the automotive, space and aircraft, and shipbuilding industries. Whether your product requires a single cavity, open and shut mould, or a complex, multi-cavity, multiple-gate, multiple-action tool, Ideal Rapid can handle your job. Talk to one of our expert team and contact us to get your free quote.