DEDICATED RAPID TOOLING MANUFACTURER IN CHINA

RAPID TOOLING MANUFACTURER: THE ULTIMATE FAQ GUIDE

Tooling is a critical step in manufacturing. The process involves making tools used to create a product, such as cutting equipment, dies, jigs, and molds.

There are different techniques used in tooling. The right choice of tooling is dependent on these basic factors: cost, quality, and speed.

Rapid tooling is one of the processes used. The process is widely accepted by designers, engineers, and manufacturers because of its lower cost, fast speed, and ability to use different materials.

The truth is that there are several reasons designers and manufacturers use rapid tooling. For instance, it is effective, low cost, and quick. Thus, you can be assured your products get to the market faster.

Traditionally, the development of tools and molds is by heat treatment and machining. Unfortunately, this required significant associated costs and substantial calendar time. In addition, changes to molds and tools required significant costs and time.

Therefore, the ability to quickly develop molds and parts for moderate volume production is rapid tooling. There are different reasons for the need to develop products rapidly and get them to the market before your competitors.

What Is Rapid Tooling Manufacturing?

Rapid tooling is also called soft tooling or rapid tooling. It is pared to mold tooling with the aim of enabling manufacturers to cheaply and quickly make parts.

Ideally, it is an injection mold tooling technique that makes it possible to inexpensively and quickly enable testing of parts. As a result, any method that makes this possible can apply.

A rapid tooling manufacturer embraces this technique for the validation of parts in different product development stages. Other processes can equally be used, such as die-casting, CNC machining, and 3D printing. The competitive advantage for rapid tooling lies in the materials and processes.

Rapid tooling manufacturers use actual grades of material to give a picture of how parts behave in real-life applications. In this way, you can confirm whether you have selected the right materials.

Since parts are formed through injection molding like in normal production, you can use them for impact and stress testing. For instance, a rapid tooling manufacturer can explore weak areas due to weld spots and imperfections from the injection molding process.

Engineers can use the information to determine whether changes are required before the start of mass production tooling. Manufacturers utilize rapid tooling to test different parameters to ensure parts act as required.

Rapid tooling allows product designers and engineers to discover future process flaws. They can then re-design the products and take measures to prevent problems from arising.

The truth is that there are different reasons for using rapid tooling. It is cost-effective when it comes to manufacturing injection molded parts. With high-speed, it becomes possible to get parts quickly.

Various approaches are used in rapid tooling, depending on part requirements. The aim is to reduce production costs and time.

Rapid tooling has a bright future based on the recent developments in manufacturing. Ideally, new processes and systems are introduced regularly. In the future, it will even be quicker to make a mold.

How Is Rapid Tool/Mold Used In Die Casting Production?

The mold is a closed vessel where molten metal gets injected at high temperature and pressure. It is then rapidly cooled until the solidified part or component can be ejected.

To ensure longevity in operation, the rapid tool or mold ought to be made from high-quality materials. It is then heat-treated to appropriate hardness. The dimensions of the cavity and die should be machined to the required specifications.

You should note that the customer’s requirements affect the type, features, size, and cost of tooling. Things that matter in tooling decision include the weight of die, finish requirements, number of cavities, and many more.

There are different types of die casting depending on the needs of the customer. Ideally, the choice for the type of die casting is determined by things such as:

• The volume of parts needed
• Size of the component to be cast
• Need for core slides
• Need for cast-in inserts

Production dies are the most commonly used. They include a single-cavity die and multiple-cavity die. These dies are made to critical dimensions.

You should note that the features of the cast component determine the complexity of the die. A simpler part is associated with a lower cost of die casting tool.

It is advisable for a customer to look at the overall manufacturing cost. The rapid tooling manufacturer will help the customer to examine the component’s castability and associated secondary options.

Although die cast tooling is expected to exhibit high integrity and strength, certain product requirements may call for extra steps. For instance, the need for minimizing porosity, techniques like eliminating thick wall sections are necessary.

What Is The Difference Between Rapid Prototyping And Tooling?

Rapid prototyping refers to different additive manufacturing techniques for making different specimen parts and components. On the other hand, rapid tooling speeds up part manufacturing. It utilizes different additive manufacturing techniques to make parts and molds.

The rapid prototyping process starts by creating a solid model and then converting it into an STL file. On the other hand, rapid tooling starts with the creation of a 3D file.

Some of the rapid prototyping types include stereolithography, direct metal laser sintering, selective laser sintering, and fused deposition modeling. It can also be aided by CNC machining, investment casting, and vacuum casting. Whereas, rapid tooling techniques include metal spraying, epoxy coating, aluminum casting, and more.

Rapid prototyping has its share of advantages. For instance, it reduces or eliminates risk, allows for input of user feedback. On the other hand, it has its shortcomings, such as added initial costs, lack of accuracy, and needs skilled labor. Some of its shortcomings can be addressed by rapid tooling. For instance, rapid tooling is quick, simple, and cost-effective.

Remember that rapid tooling is relatively a newer technology than rapid prototyping and indeed it is an extension of rapid prototyping.

The main similarity between these two processes is that they involve additive manufacturing. However, other processes, such as subtractive manufacturing, can be used.

What Are The Types Of Rapid Tooling?

Silicone Rubber Molds

You should note that silicone is quite versatile, although a bit expensive. It can be molded to create a cavity. Silicone rubber molds are widely used in making epoxy or urethane prototypes.

The good thing about silicone rubber tooling is that it offers amazing part cosmetics and inexpensive molds. Also, it allows for the use of a wide range of materials. You can use this process for both large and small parts.

The challenge with this process is that the properties of urethane materials vary from thermoplastic materials that are used in production. Also, because of labor demands and material cost, the individual component prices are quite high.

Aluminum Die Cast Tooling

Usually, aluminum die cast tooling is made up of the feeding side and ejector side. Tooling used can be temporary or permanent. The good thing about permanent tooling is its ability to re-use. Whereas, the temporary one is discarded.

The technique required to make the mold varies depending on the application of the component, aluminum alloy used, and dies.

The first step is to design the mold or rapid tool. In this case, the data and specifications are spelt out. Also, tolerances ought to be measured.

No matter the technique used, supervision is necessary when there is a need to produce components with tight tolerances. Also, the parts undergo machining or finishing processes before they can be assembled to make a mold or tool.

Ideally, the service life varies from 50,000 to 150,000 shots. The service life is dependent on the frequency of use, temperature range, and level of machining needed.

There are different ways to increase the service life of the aluminum die-cast tool. Lack of maintenance may result in non-uniform die casting parts. Sometimes heat treatment for aluminum die casting tooling is necessary. In this case, the mold is heated and then chilled to achieve the intended results. However, care is necessary to avoid the burning of the mold.

You should note that the maintenance of aluminum die casting tooling is important. Other than improving the service life, it ensures the molds work efficiently.

The good thing about aluminum die cast tooling is that it makes casting an easy process. Nevertheless, it ought to be done with a lot of care as each stage has an effect on the end result.

Although this type of rapid tooling has high associated initial costs, it is cost-effective in the long-run. As a result, it is the best method for large-scale production.

Spray Metal Tooling

This process is used in soft tooling. It gives a component of the rigidity it needs for use in its application. The main challenge with this process is that it produces parts with high internal stresses.

With this technique, you can make large parts quickly. Also, this tooling process is highly accurate and results in minimal shrinkage.

Epoxy Tooling

The process has similarities with vacuum casting. Rather than using silicone rubber, it uses epoxy-filled aluminum. After the mold is created, components can be made in the intended material choice.

This tooling process is easy and provides high mechanical strength and low shrinkage properties. It can also be used with different hardeners to provide desired outcomes.

Direct AIM Tooling

The process involves building a cavity on a stereolithography machine. The method may not be as hard or strong as conventional tooling; you can inject various thermoplastics into the cavities. This method is suitable for lower melting point and less abrasive polymers.

With this process, you can produce various parts using thermoplastics. However, the risk of failure and lower tool strength are the main disadvantages.

SLS Rapid Steel

In this case, tool cavities are built directly through the laser sintering technique. The method means cavity and core geometries are made and sent to the machine.

This process makes it possible to produce durable mold, which is used in die casting and injection mold tooling applications. Also, the process makes parts with complex geometries.

What’s The Difference Between Rapid Tooling And Mass Production Tooling?

Mass production tooling can refer to a wide range of things. Moreover, several processes are used. On the other hand, rapid tooling supports rapid prototyping.

You will find rapid tooling quite effective for developing product models and troubleshooting existing problems. Ideally, it is not applicable to large-scale manufacturing.

Before you choose between mass production tooling and rapid tooling, you ought to look at the main differences. These include:

Speed

The truth is that rapid tooling is faster as compared to mass production tooling. That makes it useful where the production of small tools is time-sensitive.

Making of the prototype and validating it make rapid tooling suitable for rapid prototyping. Moreover, multiple iterations can be made.

Cost

The truth is that rapid tooling is more cost-effective as compared to mass production tooling. Also, less amount of material is needed in rapid tooling and mass production tooling。

Since much of the process is machined by machines and computer applications, the risk of human error is reduced. In this way, wasted labor and resources are reduced.

Quality

Unlike mass-production tooling, rapid tooling produces tools that have shorter lifespans and less durable. As a result, the tools have an impact on the durability of the parts they make. However, this is not always a disadvantage, as some parts should not last long. Therefore, it can be a waste to spend money to guarantee durability.

Usually, a customer may be at liberty to choose between rapid tooling and mass production tooling. For instance, you can start with rapid tooling and then move to rapid manufacturing. You should consult a rapid manufacturing producer first.

Why Should You Consider Rapid Tooling For Your Prototypes?

Rapid tooling has got its way into the manufacturing industry. That explains why it is used by prototyping industries to reduce lead time. Using rapid tooling in making prototypes becomes a critical part of the product development cycle. For instance, it helps produce marketing samples, production process design, and evaluation purposes.

These are some of the reasons you should use rapid tooling in the rapid prototyping process:

• Meet custom mold for different applications
• Fast prototyping products
• It is cost-effective
• Provides short tooling time
• Eliminate troubleshooting of problems
• Discover future problems
• Supports a wide range of materials
• It is possible to consolidate complex and hard assembly into a single process
• Makes it easier to develop models with complex shapes and surfaces

What Materials Can Be Used For Rapid Tooling?

Various tools can be made through rapid tooling. When choosing a material, you ought to consider several things, such as, melting point, density, cost, strength, and resistance to corrosion. The following are materials that are widely used in rapid tooling.

Aluminum

Aluminum cast parts are common in automotive parts. They can also be used in the computing and communication industries. Other than being lightweight, they can withstand high temperatures.

Also, aluminum cast prototypes have excellent resistance to corrosion and easy to cast. The alloys have high thermal and electrical conductivity. Another thing good about aluminum is that it is fully recyclable.

Magnesium

Magnesium is a strong, lightweight, and recyclable metal. It is useful for applications where extended lifespan and lightweight are vital parameters. It has a low density, excellent finishing characteristics, and thermal conductivity.

Zinc

Zinc is widely used in telecommunications, computing, and automotive industries. It is cheaper than most materials used in rapid tooling and it is fully recyclable. Moreover, it provides smooth surface finishing, allowing painting and plating.

ABS

ABS is an amorphous and thermoplastic polymer. The fact that it is thermoplastic means that it responds to heat as it changes to liquid at 221 degrees Fahrenheit. It can also be heated to the melting point, re-heated, and then cooled.

Rather than burning, ABS plastic liquefies. As a result, they can be injected into the mold and recycled. ABS has excellent resistance to physical impacts and corrosive chemicals. Also, it is easier for the machine and has a low melting temperature, making it suitable for injection molding.

In rapid tooling, it is reinforced with glass fiber.

PA6

This material is commonly known as Nylon 6. Ideally, it is widely used as an engineering thermoplastic. It has excellent chemical resistance, abrasion resistance, rigidity, high strength, and fatigue endurance. That explains why it is used in making bearings and structural applications.

It is used in rapid tooling because it is a plastic performance with a good surface finish and a high degree of toughness.

What Are Rapid Tooling Advantages?

There are multiple direct and indirect benefits of rapid tooling for manufacturing companies. That explains why the process is quite popular. Ideally, by saving money and time on mold manufacturing and prototyping, you can enjoy different benefits. For instance, you can increase ROI and the quality of the product. These are ways businesses can benefit from rapid tooling.

Faster Time to Market

If you can get through the molding and prototyping process, the earlier, you can get the product to the customers. Ideally, you do not have to wait for conventional tooling that takes months to create a prototype.

By making a digital model of the mold or tool, it becomes easier to automate the process. In this way, you can test the design and validate the product before moving to mass production.

Advanced Design Testing

With rapid tooling, you can make different molds and prototypes within a short period. Thus, a rapid tooling manufacturer has adequate freedom to make adjustments and the freedom to test new ideas.

Ideally, if it takes several weeks to make a prototype, you may find it difficult to change the design even if it improves the product. The fact that you can experiment with different prototypes within a short period, you can innovate.

Various Types of Materials

Another reason for rapid tooling is that businesses can leverage the use of injection molding parts. That is because rapid tooling helps create custom molds. As a result, you can create different parts from the mold.

The good thing about rapid tooling is that you can test various types of materials. If you are not sure which material best suits a given application, you can make different prototypes from different materials.

Increased ROI

The truth is that it does not cost much to hire a rapid tooling manufacturer in China. That is the case when you compare it with having to hire experts to shape molds or prototypes manually. Rapid tooling will help save production costs.

Easily Accessible

This is one of the underrated benefits of rapid tooling. In fact, you can now easily access rapid tooling services. Experienced product developers have a wide range of rapid tooling resources such as 3D printers, robotic systems, and CNC machines.

As a result, rapid tooling is now not only for large companies with lots of resources. Even if you are running a small business, you can access these services.

When you work with a skilled rapid tooling company, you will have access to advanced and efficient tools and machinery. Therefore, you can take your business to another level.

Although rapid tooling has many advantages to offer, it is not the right solution for every project. For instance, the molded parts or prototypes made may not be precise as those made with other tooling techniques.

Technologies such as CNC machining are making it possible to make complex parts with lots of precision and accuracy. That means there is no need to spend a lot of time perfecting your prototype to create high-quality products.

The most important thing is to find a reliable rapid tooling manufacturer that you can trust. The manufacturer works with you to determine whether rapid tooling is necessary for your project.

Cost Savings

Rapid tooling is known for offering cost savings. The part that is made with rapid tooling is that it supports mass production. As a result, you can subject the parts and components you get into different tests. The results from testing mean you can determine the changes required before you start the full-scale tooling process.

What Are The Limitations Of Rapid Tooling?

Most rapid tooling processes are limited to a tolerance range of +/- 0.005 to +/- .010. For critical dimensions, it is vital to design additional stock.

You should note that many rapid tooling techniques are limited to the physical size of inserts that can be made. Therefore, the cavity size is quite important in this case.

Also, some rapid tooling methods have a limitation of the tool life. This is because of the materials of cavity inserts. However, this can be improved by surface treatments or coatings.

Rapid tooling techniques require considerable investment in equipment. That is the case if a business wants to do the work in-house. Fortunately, businesses can outsource the work to a reputable rapid manufacturer such as Sunrise Metal.

As new developments are realized in rapid tooling, new processes will emerge. Such processes will improve RT strengths and eliminate weaknesses.

What’s The Lead Time Of Rapid Tooling?

Improving design flexibility and reducing lead time are some of the benefits of rapid tooling. That explains why this manufacturing process is becoming popular with businesses that want to improve their efficiencies.

Remember that speed is quite important in business. Whether it is developing critical components or supplying just-in-time for automotive manufacturers, the demand for a short lead time keeps growing.

The lead time for rapid tooling depends on a multitude of factors. For instance, it depends on geometry complexities and the size of the tool. Also, the tooling technique used does matter. Therefore, the lead time varies from one project to another.

Simple designs have shorter lead times. Remember that the shortest lead time does not guarantee a high-quality tool. There is a need to deliver high-quality tools within the shortest time possible.

In most Chinese factories, rapid tooling takes several weeks. However, at Sunrise Metal, the lead time is reduced by over 50%. Depending on the number of tools ordered, it can take about 1 to 2 weeks.

The following are some of the things that affect the lead time for rapid tooling:

Information

Information you provide to the manufacturer can affect the cost and price of tooling. Incorrect or little information increases the lead time because of back and forth communication.

Materials

Materials you want to be used affect the cost of the product and the duration it takes to manufacture it. For instance, a given material can cost more because of its chemical, physical, or mechanical properties.

Engineering

The engineering process involved in manufacturing determines the lead time. Even a meticulously engineered component may need extra services when it gets to a rapid tooling manufacturer.

Extra Services

Extra services such as surface finishing can increase both the price and lead time. With rapid tooling, an order ought to be fast-tracked to reduce lead time to a few days.

Testing

Quality prototypes rely on the quality of parts and components. Reputable manufacturers ensure they test the product before shipping. This may increase the lead time.

How Cost-effective Is Rapid Ttooling Service?

Rapid tooling plays a critical role in manufacturing. The process makes it possible to prepare various parts of the functional model from the CAD data at a lower cost and less time. Ideally, it is a channel for making injection molded parts.

You should note that the rapid tooling cost is quite low when you compare it with conventional machining techniques. That is because it serves as a bridge to making injection molded parts.

Remember that rapid tooling utilizes a rapid prototyping model to fabricate tools for a limited volume of prototypes. However, it is not effective for mass production.

The truth is that the rapid tooling technique is economical and quick. During the product development cycle, it helps the production of a certain quantity of functional tests or prototypes. For instance, it can be used to make samples for marketing.

It is estimated that rapid tooling cost is about 10% lower than conventional tooling costs. However, the durability of the tool life is less as compared to conventional tools.

What Makes Sunrise Metal Rapid Tooling Unique?

Sunrise Metal has many years in rapid tooling and rapid prototyping services. Our skilled engineers offer premium quality rapid tooling accurately and quickly. The company is dedicated to meet the needs of its clients in the best way possible.

Sunrise Metal’s rapid tooling service is designed to serve both small and medium production requirements. Whether you have simple parts or complicated components with tight tolerances, you can enjoy low-cost services.

Rapid tooling service in China provides you the opportunity to support innovation and new products. Sunrise Metal is the leading rapid tooling company in China that can handle different technical aspects of products.

Sunrise Metal’s rapid tooling service gives your business a competitive advantage in the following ways:

• It is a fast and quick method for making prototypes
• Allows for easy modifications for the prototype
• Machining may not be necessary
• Minimal wastage of materials
• Fully functional prototype
• Reduces the time it takes to get a product to the market

If you are looking for a rapid tooling service, Sunrise Metal is the better option. It provides quick turnaround, cost-effective, and quality rapid tooling service to its customers from all over the world.

How Does Sunrise Metal Control Rapid Tooling Quality?

Quality is the most important priority at Sunrise Metal. The company strives to exceed customer expectations and requirements by delivering on-time.

Sunrise Metal adopt a continuous improvement quality strategy. As a result, the emphasis is put on teamwork, training, and education.

Sunrise Metal takes its quality assurance to its customers seriously. That explains why it implements the QMS system. In this way, it ensures all activities, materials, processes, and technology used meets both regulatory and client requirements.

The company ensures all defects are eliminated at the design stages and during manufacturing. Also, its processes are continuously improved to meet international standards.

The fact that the company has been in this industry for over 10 years is a sign of its commitment to providing outstanding services. For instance, the company is IATF 16949 and ISO 9001 certified manufacturer. All these demonstrate its commitment to meeting internationally accepted quality standards.

Sunrise Metal has invested heavily in quality inspection machines. Some of its machines and devices include an X-ray detector and Zeiss CMM.

How Long Does a Rapid Tool Last?

It is vital to note that rapid tool is subjected to wear and tear. As a result, its lifespan reduces whenever it is used. However, a single tool can be used to make thousands of components depending on material and application.

Some rapid tooling applications ensure no damage occurs to tool inserts after successive thousands of injections. The lifespan of a tool or mold is evident when signs of cracks, fracture, or wear start to become noticeable.

What Is a Rapid Tooling Application?

You should note that rapid tooling is an application of rapid prototyping.

This process utilizes minimal planning to support rapid prototyping. For this model to be successful, there is a need to ensure all tools or prototypes made are reusable.

Manufacturers use this process to make certain prototypes. In this way, the process helps in the design and development of manufacturing processes before mass production.

In the past, rapid tooling was widely used in the automotive industry. However, it is now used in other industries such as aerospace, education, and healthcare.

The truth is that rapid tooling supports different applications. Moreover, new applications are emerging with the discovering of a new manufacturing process.

Rapid tooling can be used to make molds – whether metallic or non-metallic. It can also be used to make different casting cores and shapes.

Why Is Design For Manufacturing Important In Rapid Tooling Service?

Design for Manufacturing (DFM) plays a critical role in the product development cycle. The process involves optimizing the design of a tool or mold for the rapid tooling process. Ideally, it helps match the design requirements of the tool to the rapid tooling technique used.

By employing DFM methods, you can reduce the difficulty and cost of making a part and maintain its quality. DFM is quite important in rapid tooling in the following ways:

Cost Reduction

As you know, a large percentage of manufacturing costs can be linked to design decisions such as manufacturing methods and choice of materials.

On the other hand, about 30% of product cost is associated with production decisions such as tool selection and planning. Therefore, there is a need to focus on DFM to minimize the total cost of manufacturing.

Streamlines Tooling

When you implement DFM from the start of the product development cycle, you can minimize re-design work, speed up to the market, and improve overall product quality.

Design Simplicity

With DFM, you can simplify your mold or tool design to help reduce inventory and time required to make products. For instance, you can reduce assembly and machining steps.

Meet Compliance Requirements

You should note that tooling errors can damage equipment or parts. By ensuring there are no errors, you can reduce shutdown and yield. For instance, you can change designs to accommodate tolerance and misalignment.

Reduce Set-Up Time

With DFM in rapid tooling, it becomes possible to minimize setup time. Also, you can reduce the number of processes to be done by part.

What Can Sunrise Metal Do After Rapid Tooling?

Sunrise Metal is your one-stop-shop for various manufacturing services. Other than rapid tooling, the company offers other services that include rapid prototyping, die casting, CNC machining, surface finishing, and more.

Sunrise Metal is the leading rapid prototyping company in China. The process involves testing designs and validating them whether the end-product will work as required. When you seek this service, your product will be completed with high accuracy.

The manufacturer makes spot-on prototypes at a lower cost and fastest time possible. As a result, clients, engineers, and designers can evaluate the prototype.

Sunrise Metal also offers a die casting service. The company can meet medium and low volume die casting production orders.

Also, Sunrise Metal offers CNC precision machining services. Ideally, the company offers various machining procedures with automation capability on processes such as turning, tapping, drilling, and milling.

Before the products are shipped to you, they undergo surface treatment processes. This is necessary to improve features and specifications for different applications. It can also be done purely for aesthetics.