Injection molding is one of the most popular manufacturing processes for thermoplastic, silicone, or rubber parts. Due to the excessively high costs of traditional metal tooling, it is also the process that can benefit most from rapid tooling.
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With affordable desktop resin 3D printers and temperature-resistant 3D printing materials, it is possible to create 3D printed injection molds in-house to produce functional prototypes and small, functional parts in production plastics.
For low-volume production (approximately 10- parts), 3D printed injection molds save time and money compared to expensive metal molds. They also enable a more agile manufacturing and product development approach, allowing engineers and designers to create functional prototypes or low-volume end-use parts to validate material choice and continue to iterate on their designs with low lead times and cost before investing in hard tooling.
Stereolithography (SLA) 3D printing provides a cost-effective alternative to machining aluminum or steel molds. SLA 3D printed parts are fully solid and isotropic, and materials are available with a heat deflection temperature of up to 238°C @ 0.45 MPa, meaning that they can withstand the heat and pressure of the injection molding process.
Shenzhen-based contract manufacturer Multiplus uses 3D printed injection molds with the highly glass-filled and heat resistant Rigid 10K Resin on Formlabs resin 3D printers, shortening lead times for small batches of around 100 injection molded parts, from four weeks to only three days.
As an alternative for mid-volume production of about 500 to 10,000 parts, machining molds out of aluminum can also reduce the fixed costs associated with manufacturing molds. Machining aluminum is five to ten times faster than steel and causes less wear on the tooling, which means shorter lead times and lower costs. Aluminum also conducts heat faster than steel, resulting in less need for cooling channels and allowing manufacturers to simplify mold designs while maintaining short cycle times.
Many businesses turn to SLA 3D printing to create molds for thermoforming processes, because it offers a fast turnaround time at a low price point, especially for shorter runs, custom parts, and prototype designs. 3D printing also offers unmatched design freedom to create complex and intricate molds. Use the Form 4 desktop SLA printer to produce smaller molds, and the Form 4L large format 3D printer for mold sizes up to 35.3 x 19.6 x 35 cm (13.9 x 7.7 x 13.8 in).
Product development firm Glassboard leverages the fast print speed of Fast Model Resin to quickly produce molds and thermoform polycarbonate prototypes such as helmet shells or packaging. They can achieve complicated mold shapes that would be difficult to manufacture traditionally, including small features and holes for an even better vacuum distribution across the surface.
Cosmetics manufacturer Lush used to craft the master molds for their popular products by hand. But recently, they turned to 3D printing to create vacuum forming molds for detailed and textured designs, which allows them to take ideas from concept to reality in under 24 hours, and test more than a thousand design ideas each year.
High-performance composite materials such as carbon fiber can also be hand laminated on 3D printed molds. SLA 3D printers offer a smooth surface finish that is essential for layup molds.
The Formula Student team of TU Berlin hand laminates carbon fiber parts on 3D printed molds for racing cars. Printed with Tough Resin, the mold is not only strong and supportive during the layup but also sufficiently flexible to separate the part from the mold after curing, unlocking design possibilities.
Google’s ATAP team used 3D printed stand-ins, or surrogate parts instead of overmolded electronic sub-assemblies for the initial tool tuning at the factory.
Designers at the Google Advanced Technology and Projects (ATAP) lab were able to cut costs by more than $100,000 and shorten their testing cycle from three weeks to just three days using a combination of 3D printing and insert molding. Google ATAP’s team found that by 3D printing test parts, they could save time and money over using expensive electronic parts that had to be shipped in from a supplier.
Dame Products, a Brooklyn-based startup, designs products for the health and wellness industry. They employ silicone insert molding to encapsulate internal hardware for customer beta prototypes. The Dame Products product line incorporates complex ergonomic geometries fully encapsulated in a layer of skin-safe silicone in vibrant colors.
Engineers prototype dozens of insert and overmolded devices in a single day by rotating through three or four SLA 3D printed molds. While the silicone rubber of one prototype is curing, the next can be demolded and prepared for the next fill; the finishing and cleaning of demolded prototypes happens in parallel. When prototype hardware is returned to the company, the beta device is bleached, the thin silicone layer removed, and the internal hardware is reused in a new beta prototype.
3D printed rapid tooling for compression molding can be leveraged for the production of thermoplastic, silicone, rubber, and composite parts. For prototyping small or medium-size parts, 3D printing may be the cheapest and fastest method for creating molds. Multiple iterations can be made quickly with CAD software, reprinted, and then tested. 3D printing is most commonly used for compression molds intended for heatless applications.
Product developers at kitchen appliance manufacturer OXO use 3D printing for prototyping rubbery components such as gaskets by compression molding two-part silicone using 3D printed molds.
Engineers, designers, jewelers, and hobbyists can capitalize on the speed and flexibility of 3D printing by combining metal casting processes like indirect investment casting, direct investment casting, pewter casting, and sand casting with 3D printed patterns or casting metal into 3D printed molds. Casted metal parts using 3D printed rapid tooling can be produced in a fraction of the time invested in traditional casting and at a significantly lower cost than metal 3D printing.
Stereolithography 3D printers offer high precision and a broad material library that is well-suited for casting workflows and can produce metal parts at a lower cost, with greater design freedom, and in less time than traditional methods.
Traditionally, patterns for direct investment casting are carved by hand or machined if the part is a one-off or expected to be only a handful of units. With 3D printing, however, jewelers can directly 3D print the patterns, removing the design and time constraints common in other processes.
Similar to investment casting, 3D printing can be used to create patterns for sand casting. In comparison to traditional materials like wood, 3D printing allows manufacturers to create complex shapes and go straight from digital design to casting.
With 3D printing, manufacturers can also directly 3D print the mold for their pattern using materials like High Temp Resin or Rigid 10K Resin, resins with high-temperature resistance. The same method can also be used to create molds for direct pewter casting.
Beyond metals, casting is also a popular method for producing silicone and plastic parts for medical devices, audiology, food-safe applications, and more.
Medical device company Cosm manufactures patient-specific pessaries for patients with pelvic floor disorders. They 3D print molds on an SLA 3D printer and inject biocompatible, medical-grade silicone into it to create the part. Rapid tooling with 3D printing allows them to create custom parts without the high costs of traditional tooling.
3D printed rapid tooling presents some interesting properties for sheet metal forming as well. Characterized by high precision and a smooth surface finish, SLA 3D printers can fabricate tools with excellent registration features for better repeatability. Thanks to a broad material library with various mechanical properties, choosing a resin tailored to the specific use case can optimize the result of the forming. SLA resins are isotropic and fairly stable under load compared to other 3D printing materials. Plastic tooling can also eliminate a polishing step, as plastic dies do not mark the sheet as metal.
3D printing is the fastest and most affordable way to produce rapid tooling for a variety of applications. As we saw in the previous examples, both direct and indirect rapid tooling leverages 3D printing in different ways to develop functional tools, such as molds, patterns, and dies for a variety of traditional manufacturing processes.
From the different 3D printing processes, SLA 3D printers offer the most versatile solutions for tooling. SLA 3D printed parts are accurate, watertight, have a smooth surface finish that is ideal for molds, and can replicate small details for complex molds and patterns.
Machining is one of the most common methods for manufacturing conventional tooling and hard tooling, but it can also be leveraged for creating rapid tooling. Instead of durable metals such as steel or nickel alloys, rapid tooling is most commonly machined out of tooling board, wood, plastic, or aluminum.
Compared to 3D printed tooling, machined tooling out of soft materials can be more efficient for large-format tooling and simple shapes, but it gets increasingly labor-intensive and expensive in line with design complexity. Aluminum tooling is more durable and is generally used for low to mid-volume production, especially for injection molding.
Machining tools are more expensive, require a trained operator, and have a complex workflow for in-house production compared to 3D printers, especially for one-off parts like consecutive prototype iterations of rapid tooling. As a result, many companies outsource machining to service providers, but this comes with an often multiple weeks-long lead time and the rapid factor of rapid tooling quickly diminishes.
Rapid Tooling is an advanced method that involves the practice of rapid prototyping techniques and conventional tooling to manufacture a mold quickly
Rapid tooling consumes less time and cost than a conventional tool and is changing the way we bring products to life. This process can significantly cut down lead times to as little as 24 hours, a stark contrast to the traditional 4-8 weeks, thereby drastically reducing costs for manufacturing runs that range from just one to 10,000 parts. Industries across the board have adopted rapid tooling to compress their time-to-market, with some direct rapid tooling processes capable of producing approximately 5,000 parts depending on the material complexity.
When we compare the rapid tooling process with another traditional mold making, it can help you save 40% to 50% of the cost and 40% to 60% of the time.
We can say that rapid tooling is the most convenient and cost-efficient process in comparison with the old-fashioned manufacturing methods.
What makes it even better? It bridges the gap between prototyping and mass production, helping you scale faster while keeping quality high. As manufacturing keeps evolving, rapid tooling is becoming a go-to solution for businesses that want to stay ahead.
In a nutshell, if you want to promote your products in the market at the right time, then the rapid tooling process can be a great help that can able to produce multiple parts out of alternative materials.
In order to get the best rapid tooling services, you must engage a responsible manufacturer that always examines product structure, tooling building viability, and potential quality risk to make you satisfy. As a result, it ensures the tooling is benign.
In this article, we’ll focus on how rapid tooling works, why it’s so effective, and how you can use it to speed up your next project.
Rapid tooling, often referred to as “soft tooling” or “prototype tooling,” is a dynamic manufacturing process used primarily for short runs or early-stage design iterations. It harnesses the capabilities of additive manufacturing and CNC machining to swiftly produce tooling like molds, patterns, and dies at a reduced cost.
Typically, materials such as aluminum, soft steels, or high-temperature polymers are employed to create molds that can handle anything from a few test pieces to thousands of production parts. However, it’s worth noting that while rapid tooling accelerates development time, the longevity of the tools may be compromised if made from lower-quality materials.
A rapid tool is a physical mold, die, or pattern that is produced swiftly using cutting-edge technologies. This could range from an insert to a fully assembled mold base.
Notably, some rapid tools incorporate 3D-printed mold inserts made from heat-resistant resins that can endure injection molding temperatures up to approximately 240 °C at 0.45 MPa.
While these tools offer quick turnarounds in production, they may exhibit limited dimensional accuracy if not post-processed or if constructed from lower-grade resins.
Ensuring the smoothness of molds is crucial to mitigating defects such as flashing or warping in the final products, emphasizing the importance of quality in rapid tooling processes.
Rapid tooling emerged in the late 20th century, marking a significant shift in manufacturing processes with the advent of additive manufacturing and advanced CNC machining.
Initially, the focus was on creating simple plastic prototypes, but the introduction of more durable materials such as aluminum, soft steel, and temperature-resistant resins soon facilitated the production of short-run parts.
As technologies like Stereolithography (SLA), Selective Laser Sintering (SLS), and Direct Metal Laser Sintering (DMLS) developed, rapid tooling expanded its reach, enabling more extensive prototyping and limited production capabilities. Initially referred to as “prototype mold” or “soft tooling,” these early tools were characterized by their short mold life but allowed for faster iterations.
The s saw a surge in its adoption across various industries, such as automotive and medical, driven by the need for rapid design validation.
Rapid tooling method can be executed in-house or outsourced and is notably shorter than conventional tooling practices, often slashing lead times by 75% or more.
The process involves two primary methods: direct and indirect tooling.
Direct tooling constructs the mold or mold inserts directly from the digital designs, whereas indirect tooling involves creating a master pattern first, which is then used to produce the mold.
Techniques such as metal binder jetting have revolutionized rapid tooling by enabling the production of near-finished hard tooling within days.
Rapid tooling involves five key steps, each integral to achieving high-quality tool production swiftly:
Key considerations:
Conventional tooling and rapid tooling are distinct in several fundamental ways, particularly in terms of cost, time, and production volume. Traditional tooling involves higher upfront costs and longer lead times, often extending up to 8 weeks, and is generally utilized for production runs exceeding 5,000 parts. This method typically uses durable materials like hardened steel that can withstand hundreds of thousands of cycles.
In contrast, rapid tooling is a more cost-effective and time-efficient approach, ideal for short runs and custom part production, with the capability to complete projects within days to a few weeks. Rapid tooling often employs materials like aluminum or softer steels, which, while reducing costs and lead times, may offer a shorter mold lifespan of only a few thousand cycles depending on the specific application.
Additionally, rapid tooling allows for the creation of complex geometries and advanced cooling channels more easily than conventional tooling.
Here is a comparison of the two methods based on six main factors:
FactorConventional ToolingRapid ToolingLead TimeUp to 8 weeksDays to a few weeksCostHigh upfront costLower initial expenseVolume5,000+ parts1 to 10,000 partsMaterial HardnessHigher (steel)Lower (aluminum, soft steels)Mold LifespanHundreds of thousands of cyclesA few thousand cyclesComplexityLimited by cost/timeGreater flexibilityRapid tooling can be broadly categorized into two types: soft tooling and hard tooling.
Soft tooling, which includes materials like silicone or polymer-based molds, is suited for lower production volumes, often ranging from dozens to hundreds of parts.
Hard tooling, on the other hand, uses metals like aluminum or steel and is appropriate for higher volumes, sometimes extending into thousands.
Direct rapid tooling streamlines the mold-making process by building molds directly from CAD data, often bypassing the need for a master pattern. This method is particularly advantageous for its speed, with turnaround times ranging from 24 to 72 hours in some cases.
Direct rapid tooling can produce complex geometries that traditional methods cannot, such as internal features and cooling channels through conformal cooling techniques.
However, the molds produced may have a shorter lifespan, especially if created from polymers or other less durable materials. While direct rapid tooling is excellent for rapid prototyping and low-volume production, the molds typically handle production volumes up to approximately 5,000 parts, with variations depending on the complexity and the materials used.
3D printing (Additive manufacturing) techniques such as Stereolithography (SLA), Selective Laser Sintering (SLS), and Direct Metal Laser Sintering (DMLS) play a pivotal role in the realm of direct rapid tooling.
These methods are capable of producing mold inserts from high-temperature materials that withstand injection pressures and temperatures up to approximately 238 °C at 0.45 MPa. The primary applications of these technologies are found in industries requiring quick turnaround for complex part geometries, offering significant cost advantages for production runs of fewer than 1,000 parts.
Photopolymer-based rapid tooling, for instance, may require further finishing to achieve the desired surface smoothness. Additionally, metal binder jetting presents a durable option for “hard” tooling inserts, with post-infiltration processes enhancing their wear resistance and extending their usability.
CNC machining method is especially useful for creating aluminum or soft steel mold inserts swiftly. This method is well-regarded for its efficiency in heat dissipation and its capacity to reduce cycle times significantly.
While more durable than polymer-based inserts, CNC-machined molds demand skilled operation and precise control, particularly when working with complex mold geometries. CNC machining not only offers a quicker alternative to traditional steel tooling but also does so at a reduced cost, even for larger or more intricate molds.
Shops can deliver these CNC-machined inserts within an impressive timeframe of 2-3 days, proving essential for projects with tight deadlines.
Direct Metal Deposition (DMD) technology allows for the fabrication of near-net-shaped metal parts directly onto existing tool bases, facilitating rapid iterations and modifications in the tooling process.
This method is especially beneficial for rapid tooling applications where time constraints are critical. DMD is known for its faster build rates compared to other 3D printing methods and requires subsequent machining to achieve the precision necessary for high-quality tooling.
Its ability to apply metal in a layered fashion enables not only quick manufacturing of new tools but also the repair and alteration of existing molds, significantly reducing downtime and increasing the adaptability of manufacturing processes.
Binder jetting stands as a remarkable rapid tooling method, particularly useful in the creation of sand casting molds and metal parts swiftly. This technology shines in its ability to manage complex shapes, making it ideal for casting intricate patterns needed in the manufacturing process.
One of the pivotal benefits of metal binder jetting lies in its requirement for infiltration with materials like bronze or cobalt, which significantly enhances the density and strength of the produced parts.
This characteristic makes binder jetting a feasible option for tooling that must withstand moderate loads, thereby broadening its applications across various industries, including automotive and aerospace, where precision and durability are paramount.
Electroforming is a specialized rapid tooling technique that involves the precise deposition of metal onto a master pattern through electrodeposition, resulting in highly accurate metal shells.
This method is particularly suited for applications that require thin, intricate molds with high surface finish quality.
The produced shells are not only precise but can also achieve a highly polished surface, which is essential in industries like consumer electronics and automotive detailing.
However, electroforming may require a robust support structure to maintain the integrity of the thin metal shells during the tooling process, which adds a layer of complexity to its implementation.
Indirect rapid tooling is especially advantageous for complex designs or when experimenting with multiple mold materials.
Unlike direct methods, indirect tooling typically involves a slightly longer timeframe but compensates by producing more robust master patterns that can be repeatedly used. This method frequently employs soft tooling, such as silicone, to swiftly and economically produce multiple duplicates.
However, one must be cautious as errors can arise if multiple stencils are created, particularly if dimensions of the master pattern or mold shift due to repeated copying.
Silicone mold casting is a versatile and cost-effective method within indirect rapid tooling, often utilized for short runs of plastic or metal parts through processes like lost wax casting.
Utilizing 3D printed master patterns to create silicone molds allows for production volumes typically ranging from 10 to over 100 parts, depending on the silicone grade and part complexity.
While this method provides excellent detail reproduction, the silicone molds may degrade after repeated use, impacting the longevity and quality of the molds.
Vacuum casting uses silicone molds to produce small batches of high-quality plastic parts. This technique is praised for its ability to achieve superior surface finishes and detail fidelity, making it ideal for prototypes and end-use parts in industries such as automotive and consumer electronics.
The vacuum assists in ensuring bubble-free casts, enhancing the aesthetics and functional qualities of the produced parts.
Sand casting, a traditional method revitalized by rapid tooling techniques, involves creating sand molds through 3D printed patterns. This method is especially cost-effective compared to traditional pattern-making methods and is suitable for small to medium metal castings.
Functional prototypes and end-use parts in materials like aluminum and steel alloys are commonly produced using this technique, offering substantial savings in both time and costs.
Investment casting, a cornerstone in the spectrum of indirect rapid tooling, employs wax or resin patterns to create precise metal parts.
This age-old technique has been revolutionized by 3D printing, which slashes the time needed to produce patterns compared to traditional methods like hand carving or CNC machining. Predominantly used in the aerospace and automotive industries, investment casting is lauded for its ability to produce complex geometries with excellent surface finishes.
The method not only enhances the prototyping stages but also supports the manufacturing process by providing a cost-effective solution for low to medium volume production, marrying the intricacies of detailed design with the robustness required for functional parts.
Injection mold casting with 3D-printed patterns represents a significant advancement in rapid tooling, streamlining the traditional complexities of mold making.
By utilizing 3D-printed patterns, manufacturers can reduce lead times dramatically, making this method ideal for short-run injection molding and even final metal molds.
This approach is particularly beneficial in industries such as consumer electronics and medical devices, where time to market and design flexibility are paramount.
Selecting the appropriate rapid tooling method for your project depends on several key factors, including budget, production timeline, part complexity, and intended production volume.
Each tooling method offers unique advantages and limitations, so understanding these factors can help you make the most cost-effective choice.
A manufacturer in the aerospace industry needed durable, heat-resistant molds for small batch production of flight control surfaces. CNC-machined aluminum molds were chosen due to their ability to withstand high temperatures and produce up to 5,000 parts with minimal wear.
A medical startup required rapid tooling for 500 prototype housings used in clinical trials. SLA 3D-printed molds with high-temp resins were selected due to their cost-effectiveness and ability to produce complex internal geometries needed for the device’s unique structure.
A consumer electronics company aimed to test multiple material finishes for a new product design. Silicone molding was chosen due to its low cost and flexibility in creating multiple molds from a single master pattern. This allowed them to test and validate different finishes without redesigning the entire mold.
Advanced rapid tooling techniques push the boundaries of manufacturing speed, precision, and mold performance.
These methods blend both additive and subtractive processes to enhance efficiency and reduce cycle times while maintaining part quality.
Hybrid approaches combine CNC machining for external mold geometries with 3D printing for complex internal features. This method allows greater design flexibility, especially for parts with internal cavities or undercuts that would be difficult to machine conventionally.
Conformal cooling, where cooling channels follow the contour of the mold, is another breakthrough technique. By optimizing heat dissipation, conformal cooling can reduce cooling times by up to 66%, significantly improving production speed and part consistency.
Electroforming and electroplating are also becoming popular for rapid tooling. In this process, a metal shell is formed over a 3D-printed master pattern through electrodeposition. This creates a durable mold surface while retaining the ability to produce intricate details.
Rapid tooling relies on specialized machines and equipment tailored for precision and efficiency. The right tools depend on the chosen process and material but generally cover both additive and subtractive methods.
Common machines and equipment used in rapid tooling include:
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An RP (Rapid Prototyping) machine is a specialized device used to create physical patterns or final molds for rapid tooling processes. It plays a critical role in manufacturing by enabling faster, more cost-effective part production compared to traditional tooling methods.
An RP machine can be any additive manufacturing system capable of fabricating parts directly from CAD data, making it ideal for prototype tooling and low-volume production.
Modern RP machines, such as SLA (Stereolithography), SLS (Selective Laser Sintering), and DMLS (Direct Metal Laser Sintering) printers, can produce master patterns with complex geometries, including fine internal channels and intricate surface details.
This precision reduces the need for manual finishing steps, accelerating the rapid tooling process while maintaining part quality.
Rapid prototyping refers to the creation of preliminary models or parts used for testing and design validation purposes. The focus is on quickly producing parts for concept evaluation, form testing, and functional analysis. Rapid prototyping allows manufacturers to identify design flaws and make adjustments early, reducing development risks. Technologies like SLA, SLS, and FDM are commonly used for prototyping due to their speed and cost-effectiveness.
Rapid tooling, on the other hand, involves creating molds or tools for limited production runs or testing production-grade materials.
It serves as a bridge between prototyping and full-scale production. Rapid tooling processes such as CNC machining, 3D-printed molds, and silicone casting help produce functional parts from final-use materials, making them suitable for small to medium production volumes.
Key differences include the types of materials used, production volumes, and end-use applications.
Rapid prototyping often relies on softer materials like polymers, while rapid tooling involves harder tooling materials like aluminum or soft steel.
Rapid tooling is better suited for producing low to medium quantities, while prototyping is ideal for early design stages with limited part use.
Comparison Table: Rapid Tooling vs. Rapid Prototyping
FactorRapid ToolingRapid PrototypingPrimary PurposeLow to medium production toolingDesign validation and testingMaterial TypesAluminum, soft steel, production-grade plasticsPhotopolymers, resins, thermoplasticsVolume CapacityUp to 10,000 partsTypically under 100 partsLead Time1-3 weeks for tooling production1-7 days for basic prototypesCostHigher initial cost, lower per-part costLower initial cost, higher per-part costDurabilityHard tooling suitable for multiple runsLimited durability, suited for concept modelsLearn more about our rapid prototyping services.
Rapid tooling parameters are essential when deciding on a tooling method for low volume production or prototyping stages, as they directly impact production cycles, costs, and part quality.
Key rapid tooling parameters include:
Production volume plays a critical role in choosing a rapid tooling method. Rapid tools are commonly used for low to medium production runs, typically ranging from 1 to 10,000 parts.
Aluminum or soft steel inserts can extend mold life beyond 10,000 shots if properly post-processed or hardened.
For shorter production runs under 1,000 parts, polymer-based inserts like SLA-printed molds may be more cost-effective.
Tooling volume influences material choices, as smaller batches often rely on soft tooling like silicone molds, while larger production volumes may require hard tooling techniques using metals like aluminum or steel.
Durability directly affects the lifespan of a mold or tool during the production process. Rapid tooling is often perceived as less durable than conventional tooling due to the materials used.
Polymer-based molds, such as those made from SLA resins, can degrade after several cycles, while metal tooling like aluminum or soft steel can last longer under continuous use.
Metal-infiltrated parts, such as tungsten carbide combined with cobalt, can provide near-steel durability, making them suitable for more extensive production runs.
Post-processing methods like annealing or coating can further enhance the lifespan of rapid tools. However, rapid tooling remains ideal for prototypes or short production cycles where speed and cost are prioritized over long-term durability.
Thermal resistance is a critical factor in rapid tooling when working with production-grade materials that require high temperatures during the injection molding process.
Certain 3D-printed resins can withstand temperatures up to approximately 238°C (460°F) under 0.45 MPa, making them suitable for limited runs involving thermoplastics. Metal molds, such as those made from aluminum or steel, offer superior heat resistance and can handle higher temperature injections for longer production cycles.
Detail resolution in rapid tooling determines the precision and surface quality of the final parts. It plays a key role in achieving accurate prototypes and functional tools.
Stereolithography (SLA) and Digital Light Processing (DLP) 3D printers offer exceptional detail resolution, often capable of producing fine features with layer thicknesses as low as 25 microns. This makes them ideal for complex patterns or low-volume production requiring high accuracy.
CNC machining, while also capable of high precision, depends heavily on the tool geometry and cutting strategies used. Smaller tools can achieve finer details but may extend production time due to limited material removal rates.
Therefore, choosing the right tooling method depends on both the complexity of the part and the desired production speed.
Material cost varies significantly based on the choice of rapid tooling materials. Polymer-based options, such as SLA resins or silicone rubber, are generally more affordable and suited for low-volume production but offer limited durability.
These soft tooling materials work well for prototype tooling or market testing.
On the other hand, aluminum and steel molds have higher initial costs due to material expenses and machining complexity.
However, they provide greater durability and can support larger production volumes, making them more cost-effective for high-volume production runs. Balancing material cost with production needs ensures better cost efficiency during the tooling process.
Tool lifespan defines how many production cycles a mold can endure before degradation. In rapid tooling, lifespan varies significantly based on the material and manufacturing method.
Aluminum molds often last for several thousand shots, especially when properly post-processed or coated for enhanced wear resistance. Steel tools, commonly used in conventional tooling, can withstand tens of thousands of cycles but are less common for rapid tooling due to higher machining costs.
Polymer-based molds, such as SLA-printed patterns, are more suited for limited runs, typically lasting a few dozen to a few hundred cycles before degrading. For extended production volumes, reinforced tools or metal-infiltrated patterns are preferred.
Lead time directly impacts the speed of the product development process. Rapid tooling allows for faster turnaround compared to traditional tooling methods. In some direct rapid tooling methods, such as 3D-printed molds, parts can be produced in as little as 24 hours.
CNC machining or outsourced metal molds, however, can take several weeks due to complex setups and post-processing requirements. Direct rapid tooling techniques, such as vacuum casting or SLA mold printing, excel when speed is prioritized, while hard tooling methods may be necessary for extended production cycles requiring higher durability.
Surface finish quality refers to the smoothness and appearance of the final parts produced using rapid tooling. Achieving high-quality finishes often reduces the need for additional post-processing, improving efficiency.
Additive manufacturing processes like SLA and DLP are known for their fine detail and smooth surface finish, often requiring minimal polishing.
CNC machining can also produce near-production surface finishes but depends on tool geometry, material hardness, and machining strategy. In some cases, secondary treatments such as sanding, bead blasting, or coating are required to reach production-grade surface finish quality.
Accuracy and precision are vital for achieving consistent part dimensions, especially when dealing with complex geometries in rapid tooling.
CNC machining typically offers superior dimensional accuracy, often achieving tolerances of ±0.005 inches or better, making it ideal for production tooling where precision is critical.
Additive manufacturing methods like SLA can also achieve high precision when the print orientation and layer height are optimized. However, factors such as material shrinkage and layer stacking can affect results. Proper design validation during the rapid tooling process helps ensure accuracy across multiple production cycles.
The weight of tooling materials significantly influences handling, mold changes, and production efficiency. Aluminum, often used in soft tooling, is considerably lighter than steel, making it easier for operators to handle and reducing equipment strain during tool changes.
Lighter materials also allow for faster heating and cooling cycles, which can benefit low-volume production and prototyping stages. However, heavier tooling materials such as hardened steel offer superior durability and are better suited for high-volume production where repeated use is necessary.
Rapid tooling involves various materials suited for different stages of the product development process, from prototyping to short-run production.
Material selection affects tooling durability, part quality, and production cycles.
Both soft and hard tooling materials, as well as additive manufacturing options, contribute to the flexibility of rapid tooling in various stages of product development..
Soft tooling materials are ideal for low-volume production, prototyping, and testing applications. These materials offer flexibility for design validation and can be produced quickly with minimal cost.
Hard tooling materials are preferred for higher production volumes and demanding manufacturing processes where part quality and repeatability are critical.
Additive manufacturing has revolutionized rapid tooling by enabling the production of complex molds and parts directly from digital files. These materials are often used for low-volume production and prototyping due to their speed and versatility.
Sustainable manufacturing relies heavily on the ability to recycle tooling materials, reducing waste and cost while supporting eco-friendly practices.
When choosing materials for rapid tooling, several factors should be considered to match the material with project requirements and production goals:
Rapid tooling involves creating temporary molds or tools for faster production cycles, especially when traditional tooling would be too costly or time-consuming for the same purpose.
Key industries where rapid tooling is widely applied include:
Key use cases for rapid tooling include:
Rapid tooling provides manufacturers with several key advantages that make it a versatile choice across industries. It simplifies the transition from product design to market availability by reducing production barriers and optimizing resources.
Rapid tooling can be a cost-effective manufacturing process compared to conventional tooling, but expenses vary significantly based on multiple factors. The cost is often lower for short-run production or prototyping, but prices rise when higher durability and complex designs are required:
Cost Comparison:
Reducing the cost of rapid tooling involves balancing design choices, material selection, and production techniques. By focusing on efficiency, you can keep expenses manageable without compromising quality.
Rapid tooling allows you to accelerate the product development process by creating functional prototypes and low-volume production parts faster than traditional tooling methods. To get started with rapid tooling, you need to follow a structured approach that ensures efficiency and quality.
If you’re seeking expert guidance, 3ERP’s rapid tooling services can simplify the entire process. With extensive experience in rapid tooling and prototype mold creation, 3ERP specializes in delivering high-quality molds suitable for both prototypes and low-volume production. Their expertise ensures tight tolerances of up to ±0.01 mm, making them ideal for demanding projects.
3ERP offers both direct rapid tooling and prototype mold solutions, enabling fast turnarounds for common mold sizes. For example, a standard 300 x 300 x 50 mm mold can be fabricated and tested within just 10 days. Their engineers focus on balancing cost efficiency with superior part quality, using advanced manufacturing processes like CNC machining and 3D printing.
3ERP is able to offer two metal options: aluminum mold tooling, which is highly cost-effective and suitable for prototypes, and steel mold tooling, which can be used with abrasive, corrosive, and engineering-grade plastics and which can be used to make millions of molded parts — ideal for bridge production. Molds can be made according to DME, HASCO and LKM standards.
Get in touch with 3ERP to see if its rapid tooling and low-volume molding services are suitable for your needs.
Designing for rapid tooling involves balancing speed, cost efficiency, and part quality while ensuring the mold can endure the required production volume.
Rapid tooling allows faster mold creation compared to conventional tooling, but it demands specific design adjustments to maintain part precision and structural integrity.
When designing tools or molds for low-volume production, focus on simplifying geometries and ensuring manufacturability.
The tooling process benefits significantly from early consideration of design elements like draft angles and cooling channels.
Proper planning reduces production costs and prevents issues like warping or premature mold failure. Whether working with hard tooling or soft tooling, thoughtful design choices optimize part quality and production efficiency.
Effective design for rapid tooling ensures durability, part quality, and repeatability. Following these essential design principles can help you achieve better results:
When designing a mold for the fastest rapid tooling, engineers need to consider two stages of manufacturing.
First, they must ensure that the tooling itself can be manufactured using the chosen moldmaking technology — typically CNC machining.
Second, they must guarantee that the mold will be able to produce plastic moldings during the injection molding process.
Evaluating the design in these terms is known as design for manufacturing (DfM) analysis. At 3ERP, we carry out this analysis on all designs submitted in RfQs, ensuring that the design is feasible.
However, product designers who want to speed up the rapid tooling process should perform their own DfM analysis before submitting their designs.
Most common CAD applications offer tools for DfM analysis, allowing designers to evaluate their designs for manufacturability while they are still being tweaked. For example, SOLIDWORKS offers the DFMXpress tool for assessing designs for milling, drilling, turning, and injection molding, which covers all the important bases for a rapid tooling design.
At 3ERP, we fulfill more than 50 rapid tooling orders per month, getting through more than 10,000 prototype moldings.
Of these tooling orders, the molds we can make the fastest tend to be simpler designs — ones that do not require slides or split cavities — that easily fit within a standard machining envelope. A standard part size of around 300 x 300 x 50 mm makes for faster tooling.
For large parts, designers might consider scaling down their prototypes to accommodate a standard CNC machine build envelope.
While we operate several large-envelope CNC machines, large parts may have to wait in a longer queue to gain access to these machines, whereas standard-size parts can go straight to production on any machine.
CNC machining is the standard process for making molds via rapid tooling, with the standard tool materials being aluminum or steel. This makes rapid tooling different to production tooling, in which hardened tool steel is used almost exclusively. W
hile tool steel is more durable than aluminum and other types of steel, it is more expensive and takes more time and effort to machine.
Softer steels are a viable option for rapid tooling. However, aluminum molds are often the best choice for maximum speed — useful for quick iteration of prototypes, for instance.
This is because aluminum is, despite its relatively high strength, extremely machinable: cutting tools can pass through aluminum quickly, allowing for high feeds and speeds.
Of course, aluminum molds can still perform to a very high standard, especially when a strong grade like Aluminum is used as the tooling material.
For the fastest rapid tooling orders, engineers need to make life as easy as possible for the machinist, cutting out any unnecessary features that could add time to the machining or molding operation.
Overall, engineers can streamline the rapid tooling process by following standard machining design guidelines.
One specific way to ensure fast machining — especially on a 3-axis machine — is to avoid adding features that will necessitate extra setups. This is generally straightforward during toolmaking, as material is removed from one face of the core and cavity to realize the mold design.
Another helpful procedure is to use consistent and standard hole sizes and radius sizes. This allows the machinist to use a single, standard cutting tool, preventing extra time being added to the operation.
Finally, when ordering rapid tooling from a machine shop, it helps to be cautious with tolerances.
Specifying tight tolerances on features and dimensions adds significant time to the process, requiring extra machining time and inspection time; and while this may be important for the production parts, it is generally less of a necessity during prototyping.
One experimental form of rapid tooling involves the direct 3D printing of tooling using a technology like stereolithography (SLA) with high-temperature resins.
While we would only recommend 3D printed rapid tooling for low-importance prototypes and low-temperature molding plastics, fast progress is being made in the area of rapid tooling in additive manufacturing.
Rapid tooling offers certain environmental benefits compared to conventional tooling methods. It generates less material waste since it often involves additive manufacturing processes or minimal stock removal during CNC machining.
The ability to create tools or molds on demand also reduces the need for mass production, minimizing excess inventory and transportation emissions.
Some materials used in rapid tooling, such as aluminum, are highly recyclable, supporting sustainable manufacturing cycles.
Sand casting molds can also be reclaimed and reused multiple times, further reducing waste.
However, materials like plastic resins and some polymer filaments may pose disposal challenges due to their limited recyclability.
Rapid tooling can introduce specific defects that impact part quality and tooling lifespan. Identifying these issues early in the tooling process can help you avoid costly rework and production delays.
Below are five common problems, their causes, and ways to prevent them:
Rapid tooling is a game-changer when it comes to making parts faster and smarter. It cuts lead times, lowers costs, and lets you test production-grade materials early, helping you get from idea to product more efficiently.
Whether you’re creating prototypes, testing molds, or handling small production runs, rapid tooling gives you the flexibility to speed up your project without sacrificing quality.
Rapid tooling is all about working smarter. With technologies like hybrid 3D printing and CNC machining, rapid tools are becoming even more precise and durable, making it easier for you to create reliable parts quickly.
As the manufacturing industry evolves, using rapid tooling will keep you ahead—delivering faster results while staying cost-effective.
Rapid tooling is ideal when you need fast turnaround times. For simpler mold inserts or prototype tooling, parts can often be produced within 24 hours. More complex designs, especially those requiring CNC machining or hard tooling techniques, may take a few days to complete. Compared to traditional tooling methods, which often take weeks, rapid tooling significantly shortens the product development cycle.
The lifespan of a rapid tooling mold depends heavily on the material used. Soft tooling, such as polymer-based molds or silicone rubber, typically lasts for hundreds of shots, making it ideal for low-volume production. In contrast, aluminum molds can handle thousands of parts, especially for injection molding applications. For higher durability and precision, hard tooling like tool steel can support extensive production runs with minimal wear.