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The manufacturing process requires different tools to create the end products. Especially in the case of molding, casting, or other similar methods, expensive tools like mold, die, pattern, and fixtures are required for mass production of identical items. The cost becomes a big challenge for the prototypes and small batches.
So, here comes the concept of “Rapid Tooling,” which means manufacturing tools ( mold, dies, or similar tools) quickly using cost-effective material and manufacturing methods. It mainly aims to provide the tooling for testing prototypes before scaling the full-scale production.
Furthermore, let’s go through rapid tooling in detail, including types, benefits, applications, etc.
What is Rapid Tooling?
Rapid tooling, bridge tooling, or rapid prototype tooling all refer to making tooling in the cheapest way by streamlining the process, using cost-effective material, and reducing complexity. Although rapid tooling service mainly deals with the injection molding process, it is also applicable to compression molding, die casting, investment casting, and other processes.
Moreover, there are two types of rapid tooling; Direct and Indirect.
- Direct Rapid Tooling: It involves creating the mold or tools directly from CAD data using quick processes, mainly 3D printing. This type of tooling is for testing and prototyping purposes.
- Indirect Rapid Tooling: A pattern or master model is created using casting or molding, and then the molds are made based on the pattern. It is used in small-batch production and rapid prototyping projects.
What are the Benefits of Rapid Tooling?
Creating full-scale molds and tools in product development is not feasible economically and technically. Therefore, rapid tools are crucial to test how the design looks in physical form and to produce some hundred to thousand items to test the market.
Quick Lead Times
If the CAD design is ready, the direct rapid prototype tooling can be completed as fast as a few hours with 3D printing. Similarly, indirect tooling does not take much time. It typically takes a few days from pattern creation to mold finishing. This production speed is exceptionally beneficial for new product or prototype developers; it significantly reduces the time to market.
Cost Advantage
The tooling cost is another advantage; the simplified steps and time reduce the cost. So, it allows for iteration of the design for validation, as well as offers the flexibility of gradual scaling to startups and small businesses.
Testing of Process Variables
The rapid tooling not only tests the physical form ( features and properties) of the designed items, but it is also an instrument to test the processing variables like temperature, pressure, etc. For example, a rapid die or injection mold can be used to check the optimal injecting pressure, heat transfer rate, and speed.
Material Versatility
The rapid molds can produce prototypes and samples with actual material. For example, an aluminum rapid mold can be used for ABS, PC, and other plastics. It is beneficial to check the different grades to find the best result.
What are the Ways to Manufacture Rapid Tooling Methods?
3D printing and CNC Machining are two primary methods of creating molds and related tooling. Direct rapid prototype tooling primarily uses 3D printing, and CNC machining is used for indirect tooling.
3D Printing
It is an additive manufacturing technique where material is deposited layer by layer to build a tool or mold directly from a digital model—for example, silicone molds for vacuum casting. This quick approach minimizes the time by reducing the steps like pattern design and manufacturing before creating the actual tooling.
The advantages of using 3D printing for rapid molds and dies are as follows;
- 3D printing can produce complex and intricate molds quickly and accurately.
- It allows you to change or customize the design by just changing the CAD model.
- It costs less than other methods like CNC machining
CNC Machining
CNC machining is a subtractive manufacturing approach that makes the mold and tools by removing the material using suitable processes, milling, turning, drilling, pocketing, slotting, etc. Additionally, electrical discharge machining is also combined with CNC to create deep cavities and other complex features.
Furthermore, the advantages of using CNC machining in rapid tooling include;
- It maintains tight tolerance for all manufactured tooling items.
- High-quality surface finish, smooth cavity walls
- It can accommodate various durable materials like aluminum and steel.
- If more than one rapid mold or die is required, CNC can maintain excellent repeatability.
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Applications of Rapid Tooling
Rapid tooling is a versatile technology used in various industries to accelerate product development and reduce manufacturing costs. Here are some critical applications with examples:
Table: Rapid Tooling Applications
| Application | Description | Example |
| Prototyping | Rapid prototypes at low cost | Automotive engine parts for testing. |
| Bridge Production | Producing a limited number of parts until permanent tooling is ready. | Small batches of smartphone cases |
| Custom Manufacturing | Ideal for custom or low-volume production runs where traditional tooling is too costly | Die to cast custom orthopedic implants and surgical instruments. |
| Functional Testing | Molds to create parts for functional testing to ensure they meet performance requirements | Functional prototypes of turbine blades and airframe parts for testing. |
| Production of End-Use Parts | Producing end-use parts, especially for low-volume and complex parts. | Molds for intricate designs of high-quality jewelry pieces. |