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If plastic injection molding is fast, how is rapid injection molding different? Traditional injection molding already has short cycle times, aka the amount of time it takes to produce parts. Depending upon a parts size and complexity, a single cycle can take just a few seconds.
Thats significantly faster than CNC machining, which can take anywhere from several minutes, to a few hours, to a few days. In terms of cycle times, traditional injection molding is also faster than 3D printing, which typically takes a minimum of several minutes per build.
Rapid injection molding is considered to be rapid because the tools that it uses take less time to produce. With traditional injection molding, a complex tool can take eight weeks or longer to machine. With rapid injection molding, the tooling times are much shorter and the mold materials are less expensive.
Yet there are some tradeoffs to consider. Because of their materials of construction, rapid injection molds have a shorter tool life and cant match the part tolerances of traditional high-volume molds, which are often made of expensive hardened steel.
So, how do you know if rapid injection molding is what you need? After all, terms like fast or slow are relative. If shorter lead times are critical for your project, when do you need your parts and which tradeoffs can you make? And can rapid injection molding support design complexity?
Remember: rapid injection molds take less time to produce than traditional injection molds.
There are two main reasons to use rapid injection molding and theyre not just about speed. One is about rapid prototyping and the other is about bridge tooling.
Unlike traditional injection molding, which has lead times measured in months, rapid injection molding can put parts in your hands in a few weeks. Thats what Alea Labs discovered when the developer of smart HVAC systems partnered with Fictiv on a project.
In this rapid prototyping injection molding example, the plastic vents and grilles Alea Labs designed had many ribs at various angles. The company needed a partner that could support design complexity and shorter lead times to accelerate time-to-market. They found it in Fictiv.
Design engineers need to balance rapid injection moldings speed against other requirements.
Before you decide to go with rapid injection molding for prototypes, its best to understand how it works in terms of part design, tooling, processing, and part samples. Then, make sure you have the right partner. This article is a good place to learn about rapid injection molding, and Fictiv is ready to help when its time to start molding parts.
3D printing and CNC machining have longer cycle times than injection molding, but you wont have to wait for a tool to arrive before prototyping or production can begin. CNC machines use tools for cutting, milling, drilling, and other operations, and every shop has a suite of tools on hand, but milling a part takes much longer than molding one. So, it might take longer to 3D print or CNC machine a part, but prototyping that starts sooner can put parts in your hands more quickly, enabling you to refine your designs more quickly, too.
Yet there are other considerations. For example, will 3D printing support the same resin you plan to use during production? If not, rapid injection molding is a better choice for prototyping and youll enjoy an easier transition to production since you wont have to redesign your part for a new manufacturing method. CNC machining can produce parts with complex geometries, but so can rapid injection molding if you have the right partner.
Rapid injection mold tooling has a shorter tool life and less exacting tolerances than the tools used in high-volume injection molding. But that doesnt mean you have to sacrifice part quality to get a mold more quickly. Fictiv machines rapid injection molds from different metals or combinations of metals to balance speed against other project requirements, such as support for design complexity. The materials we use are also suitable for rapid heating and cooling injection molding.
We can help you compare traditional injection molding to rapid injection molding, and we also provide 3D printing and CNC machining services if you need them. No matter which process you choose, youll get design for manufacturing (DFM) help along with your quote. Because there are key differences between traditional and rapid injection molding, the rest of this article covers part design, tooling, processing, and part samples.
Fictiv provides DFM feedback along with your quote so that you get your parts made faster.
There are ten major considerations when designing a part for the rapid injection molding process.
Fictivs Injection Molding Design Guide examines each of these considerations in detail. Theyre the same with both traditional injection molding and rapid injection molding, but rapid injection molding raises some special concerns with material selection and part tolerances.
Injection molding materials range from commonly used polymers to specialty plastics and polymer blends. There are hundreds of different plastic resins available, and they each have different end-use properties and processing requirements. Plus, the same plastic material can come in different grades, including resin types with glass or carbon fibers.
Rapid injection molding supports many of the same plastics as traditional injection molding, but abrasive materials such as glass-filled nylon cause softer molds to wear more quickly, which shortens tool life. That doesnt mean you cant use these materials, however. In the case of Alea Labs, the company needed to use a special molding compound with a high glass content.
Corrosive grades of plastic, like PVC or POM, can also cause an injection mold to wear more rapidly. Tool life usually isnt a problem if you need prototypes or lower production volumes, but its worth considering how many parts you need. If a rapid injection mold requires repairs or replacement, it could affect your project timeline.
Rapid injection molded parts that will be used in larger assemblies need to have correct and consistent dimensions so that parts fit together. Because some degree of dimensional variation is expected in any manufacturing process, youll need to define part tolerances. These allowable variations are expressed as plus or minus dimensions and are a function of both the resin type and the mold material.
Traditional injection molds made of hardened steel can produce parts with fine tolerances and withstand production of hundreds of thousands of parts. Softer rapid injection molds wont last as long and might not be able to meet the same dimensional standards. The commercial tolerances that rapid injection molds can achieve are less precise, but youll get lower-cost parts using lower-cost molds at faster speeds.
Lets say thats what you need whats the right type of tooling material for your rapid injection molding project?
Rapid injection molded parts need tolerances that support alignment and assembly.
Rapid tooling injection molding uses tools made of aluminum, soft steels, or semi-hardened steels in various grades. They typically have a single cavity because multi-cavity tools take longer to produce. Hardened steel is sometimes used with rapid injection mold inserts, but hardened steels take longer to machine and are more expensive. Rapid injection molds can also use a master unit die (MUD) to deliver tooling quickly and less expensively, but at lower volumes and with less exacting tolerances.
Aluminum can be machined twice as fast as steel and doesnt require post-machining heat treatment together, these two factors shorten tooling times significantly. Aluminum also has excellent heat transfer properties, which can support faster cycle times. Aluminum doesnt polish as well as steel, however, and that can affect the appearance of rapid injection molded parts that need to be glossy or optically clear. And if you need tight-tolerance parts, an aluminum mold probably isnt the best choice.
Typically, aluminum molds can handle 10,000 shots or less. That might be enough for your rapid injection molding project, but aluminum molds cant handle the high clamping pressures from large injection molding presses. PEI, PEEK, and other plastics that require high processing temperatures arent recommended for aluminum molds either because aluminum doesnt maintain high temperatures well.
Thats why Fictiv generally recommends soft and semi-hardened steels instead of aluminum for rapid injection molds. Although aluminum tools can be cut in just a few days, P20 steel tooling has lead times of two weeks or less and P20 can be easily welded to support engineering change orders (ECOs), which are common during prototyping or early-stage production. For glossy or optically clear rapid injection molded parts, NAK80 semi-hardened tool steel is the best choice.
The Society of the Plastics Industry (SPI), the trade association now known as PLASTICS, defines five classes of injection molds. These classes provide a convenient way to compare plastic injection molding tooling in terms of production volume and cycles, but theyre also useful when considering rapid injection molds.
SPI Mold ClassVolumesCycles101HighOver 1 million102Medium-to-High500,000 to 1 million103MediumUnder 500,LowLess than 100,PrototypeLess than 500Based on volumes and cycles, SPI classes 104 and 105 might provide what you need. SPI Class 104 molds have hardened steel inserts for tighter tolerances, but have bases made of less expensive cast metal. SPI Class 105 molds sometimes use hardened steel inserts and are the least expensive SPI mold classification.
Rapid injection molds can also use master unit die (MUD) inserts with a standard mold frame and customized, removable inserts. MUD molds, as theyre called, can be produced relatively quickly while lowering the cost of initial tooling by as much as 66%. If cost is a consideration, a MUD mold may provide the right combination of advantages.
Ultimately, it doesnt matter how fast a mold maker can machine a tool if an injection molder cant use it to process your parts without defects. Thats why Fictivs global Quality Management System (QMS) ensures our network of carefully vetted manufacturing partners keep quality standards high, regardless of whether you need traditional injection molding or rapid injection molding.
And Fictiv can provide you with T1 samples for functional testing and dimensional measurements in just a few weeks. You can also get T2 and T3 samples if your design changes and if your design changes require mold changes, then a steel mold that supports welding could make the difference between keeping your tooling or starting over.
Theres a lot to consider with rapid injection molding, and it pays to have expert guidance to make the right decision.
With Fictiv, its simple to create a free account, upload your part drawing, and get a quote along with detailed DFM feedback. And our in-house injection molding experts will guide you from prototyping through production, making recommendations that will help you leverage the speed of rapid injection molding and meet your other requirements.
Create your account to get started.
The need for efficiency and agility in the ever-changing manufacturing landscape has led to the development of innovative processes. One of which is the concept of rapid tooling. Rapid tooling is essential in shortening the product development cycle, allowing manufacturers to quickly take their designs from idea to reality.
Rapid tooling is also known as prototype mold, prototype tooling, and soft tooling. It allows you to obtain parts easily. It stands out for its short molding cycle, low molding cost, simple process, and ease of promotion. Furthermore, rapid tooling can meet specific functional requirements while providing good overall economic benefits.
Read on to learn about the fundamentals of rapid tooling, ranging from its definition to its various applications and benefits.
What Is Rapid Tooling? Various cutting toolsThe rapid tooling process involves swiftly creating molds and tooling for manufacturing purposes. This is a vital aspect of the rapid manufacturing approach, facilitating quicker and more efficient production of functional parts and prototypes. Rapid tooling is an essential link between rapid prototyping and traditional tooling methods. It offers a cost-effective and time-saving solution.
The main goal of rapid tooling is to accelerate the tooling production process. Thereby allowing manufacturers to transition rapidly from the design phase to actual manufacturing. Through advanced technologies like additive manufacturing and CNC machining, rapid tooling makes it possible to produce molds and tools with improved precision and reduced lead time. Below, we will compare rapid tooling to other manufacturing processes in terms of cost, lead time, speed, material, and applications.
Rapid Tooling vs Rapid PrototypingRapid tooling and rapid prototyping play essential functions in the dynamic manufacturing landscape. Each contributes uniquely to the product development journey. Rapid Tooling is concerned with quickly creating production tools to ensure efficient mass production, whereas Rapid Prototyping excels at rapidly creating physical models for design validation.
Here is a table showing the contrast between rapid tooling and rapid prototyping.
Rapid Tooling Rapid PrototypingCostInitial setup costs might be higher because mold costs are required.In the world of manufacturing, the decision between CNC rapid tooling and conventional tooling is important. This is because it can have a significant impact on production efficiency and costs. Rapid production tooling excels in strength and speed, catering to industries with changing demands, whereas Conventional Tooling is the stalwart, providing stability and precision for long-term, high-volume production.
Here is a table showing the contrast between rapid tooling and conventional tooling:
Rapid Tooling Conventional ToolingCostGenerally more cost-effective for shorter production runs.Higher initial costs, potentially economical for large-scale productions.Lead timeSignificantly shorter lead times. It is ideal for quick response to market demands.Longer lead times, especially for complex tooling.It is reliable for large-scale, long-term production.MaterialVersatile in material options, adaptable to different manufacturing needs. Mold is mainly made of metal materials.Supports a wide range of materials, often with more options than Rapid Tooling.It is suitable for diverse production requirements. Mold is mainly made of steel metal.AccuracyGenerally high accuracy, suitable for production-grade tools.Offers high precision and accuracy, particularly for long-term, stable production.ComplexityCapable of handling complex geometries, suitable for intricate tool designs.Well-suited for extremely complex geometries and detailed tooling requirements.ApplicationWell-suited for industries requiring flexibility, rapid adaptation, and small to medium production. It is used for prototype only when the product development project is 90% sure to be successful.Act as sample for test before high and low volume production. Rapid Tooling vs Die Casting Molding Die cast moldStarting the manufacturing journey requires an important choice between rapid tooling and die-casting molding. They both embody distinct approaches to production. Rapid tooling, emphasizing speed and flexibility, contrasts with die-casting molding, known for its efficiency in crafting intricate parts at scale.
Here is a table showing the contrast between rapid tooling and die-casting molding:
Rapid Tooling Die Casting MoldingCostGenerally more cost-effective for shorter production runs.May have higher initial tooling costs but can offer cost efficiency for high-volume production.Lead timeSignificantly shorter lead times, ideal for quick response to market demands.Initial tooling may take longer, but once set up, production lead times are relatively short, making it efficient for large-scale production.MaterialVersatile in metal and plastic material options, adaptable to different manufacturing needs.It is suitable for various metal alloy materials, especially metals like aluminum, zinc, and magnesium.AccuracyGenerally high accuracy, suitable for production-grade tools.It offers high precision and accuracy, making it a suitable for complex and detailed parts.ComplexityIt is capable of handling complex geometries, suitable for intricate tool designs.Ideal for intricate and complex part designs, offering high-detail reproduction.ApplicationWell-suited for industries requiring flexibility, rapid adaptation, and small to medium production.Commonly used for high-volume production of complex parts in industries like automotive, aerospace, and electronics. Rapid Tooling vs Injection MoldingYou will get efficient and thoughtful service from Wingtat.
Injection molding processEach method has distinct advantages. Rapid tooling, known for its speed and adaptability, contrasts with injection molding, a method known for its efficiency in producing large volumes of intricately shaped plastic parts.
Here is a table showing the contrast between rapid tooling and injection molding:
Rapid Tooling Injection MoldingCostSignificantly less cost due to cheaper mold.May have higher initial tooling costs but can offer cost efficiency for high-volume production.Lead timeSignificantly shorter lead times, ideal for quick response to market demands.Initial tooling may take longer, but once set up, production lead times can be efficient, especially for large quantities.MaterialVersatile in material options, adaptable to different manufacturing needs. Supports a wide range of materials, particularly plastics, and can accommodate various additives for specific properties.AccuracyGenerally high accuracy, suitable for production-grade tools.Gives high precision and accuracy, making it suitable for complex and detailed parts. ComplexityCapable of handling complex geometries, suitable for intricate tool designs.Suitable for complex part designs, providing high detail reproduction.ApplicationWell-suited for industries requiring flexibility, rapid adaptation, and small to medium production.Commonly used for large-scale production of plastic parts across various industries, including automotive, consumer goods, and medical devices. 2 Ways to Make Rapid Tooling CNC lathe processingThere are two common ways to make molds using rapid tooling. They are direct and indirect rapid tooling. This section will explain the two methods and how they can they used in making molds.
Direct Rapid ToolingThe direct method of rapid tooling involves the creation of both the cavity mold inserts and the actual core. One significant advantage of this approach lies in its capacity to generate tools with geometries that would be challenging to achieve through other means. An example is the conformal cooling technique, where heat dissipation from the mold is uniform, reducing cooling times by approximately 66%. This is achieved by aligning the internal cooling channels with the contours present in the mold cavities.
Indirect rapid tooling uses additive manufacturing master patterns to make a mold or die. Although many technologies are available, soft tooling techniques are the most widely used. Soft tooling method uses silicone molds for plastic parts and sacrificial models for metal investment casting.
Testing and experimentation are the goals of indirect rapid tooling. For example, indirect rapid tooling is a great solution when you wish to test various materials and already have a detailed design. This is so that molds and multiple test tools can be made from the same master pattern with ease.
Here is a table showing the different steps you can use direct and indirect rapid tooling to make molds:
Steps Indirect Rapid ToolingDirect Rapid ToolingStep 1Model the tool or mold using Computer-Aided Design (CAD) software.The materials used for rapid tooling can be classified as soft tooling materials and hard tooling materials.
Soft ToolingSoft tooling is a versatile manufacturing approach that relies on flexible and resilient materials to create molds to produce various parts. Soft tools, as opposed to their rigid counterparts in hard tooling, are made from materials such as urethane and silicone rubber. They offer unique characteristics that make them particularly well-suited for specific applications.
Urethane is a versatile material used in soft tooling. It is known for its unique combination of flexibility and durability. Because of its exceptional flexibility, it is an excellent choice for applications requiring easy demolding, particularly when dealing with intricate and complex part geometries. Urethane is well-known for its ability to maintain durability despite its flexibility, ensuring soft tooling longevity.
Another essential material in soft tooling is silicone rubber, known for its exceptional flexibility and heat resistance. Silicone rubbers exceptional flexibility makes it an excellent choice for demolding complex shapes and parts with intricate undercuts. This property, combined with its ability to withstand high temperatures, makes silicone rubber ideal for molding applications requiring elevated curing or processing temperatures.
Hard ToolingAluminum is a lightweight metal known for its good thermal conductivity. It is particularly suitable for applications with moderate production volumes. Its lightweight nature contributes to ease of handling, while its thermal conductivity aids in efficient cooling during the molding process.
Steel, renowned for its high strength and durability, is preferred for projects with high production volumes. Its robust properties make it ideal for creating molds that must withstand extensive and prolonged use demands.
Stainless steel brings corrosion resistance to the table, making it an excellent choice for applications where exposure to moisture or corrosive environments is a concern. It combines durability with rust resistance, enhancing its longevity and suitability for various molding projects.
Titanium, known for its strength-to-weight ratio and corrosion resistance, is an advanced choice for hard tooling. It is particularly suitable for projects where a balance between strength and weight is critical
Plaster, while less common than metals, offers a cost-effective alternative in certain hard tooling scenarios. Plaster is a cost-effective material but is generally less durable compared to metals. Its affordability makes it an attractive choice for projects with budget constraints, especially when tool longevity is not critical.
Plaster is well-suited for low-volume production and prototyping. Its ease of use and mold-making capabilities make it a practical option for projects with more minor production requirements.
Applications of Rapid Tooling High-speed drillHere are the various applications of rapid tooling:
CNC MachiningRapid tooling in CNC machining involves the swift creation of tooling, such as molds or dies, to be used in the machining process. It allows for the quick production of prototypes and custom parts. Rapidly fabricating the necessary tools ensures a shorter lead time, enabling manufacturers to iterate designs rapidly.
CNC machines then use these tools to precisely cut and shape materials, allowing for the efficient production of intricate components. The adaptability of Rapid tooling in CNC machining proves beneficial for low-volume production runs where speed and customization are essential.
Die CastingIn die casting, Rapid tooling plays a pivotal role in creating molds used to produce complex and detailed parts. Rapidly fabricating these molds allows for accelerated production cycles, reducing the time required for tooling setup.
This speed is particularly crucial in the automotive and consumer electronics industries, where quick turnaround times are imperative. The rapid tooling process ensures that the molds are ready swiftly, facilitating the efficient casting of components with precision and detail.
Sheet Metal FabricationRapid tooling involves the prompt creation of tools, such as dies or punches, to shape and form metal sheets. This process is crucial for prototyping and custom enclosures. Rapid Tooling in sheet metal fabrication enables the fast production of protective casings for electronic devices and machinery.
Additionally, in the automotive industry, rapid tooling facilitates the swift creation of tools for forming vehicle panels and body components. The speed of tooling setup is essential in meeting production demands and achieving timely project milestones.
Considerations to Make Prototyping Molds CNC milling machine rough cuttingWhen venturing into prototyping molds, several vital considerations come into play to ensure effective and efficient mold design and production. These considerations include:
The choice of material for the mold is crucial. It should align with the specific requirements of the rapid prototype and the manufacturing process. Factors such as material properties, durability, and ease of machining must be considered.
Accurate size and smooth surface of the mold are paramount. The molds structure should be meticulously designed to meet the prototypes specifications. Additionally, the design must facilitate high production efficiency and easy automation.
A balance between production efficiency and cost is essential. The mold design should optimize manufacturing processes, ensuring long life, low cost, and adherence to economic considerations.
The mold structure and parameters should align with the manufacturing process requirements. Rigidity, guidance, unloading mechanisms, and positioning methods must be carefully considered to enhance adaptability.
Wear parts in the mold should be designed for easy replacement. This consideration is crucial for maintaining the molds longevity and minimizing downtime during production.
ConclusionRapid tooling is a common method that manufacturers like to use. This technique allows manufacturers to speed up product development, save time and money compared to traditional tooling methods, and quickly test and validate product designs. Time to market is shortened, product quality and design are enhanced, and customer satisfaction rises. Rapid tooling allows manufacturers to iterate and alter the product design more quickly and efficiently.
At Zintilon, we offer our clients more than just assistance with custom design preparation for the rapid tooling process, which includes CAD software-generated 3D models. In addition, we provide tooling recommendations based on various specific project-specific factors, such as the customers soft or hard tooling preferences, budget, schedule, design complexity, materials, and tolerances. Contact us right now if you need quick tooling services!
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