Understanding Prototype Tooling: From Injection Mold to Low-Volume Production

Prototype tooling is fundamental in the product development lifecycle as it connects conceptualization with production. It is a useful and efficient way to verify design performance and make stylistic adjustments without spending too much money on mass production. This paper investigates in detail the complexities underlying prototype tooling, particularly how it is used in injection molding and low-volume manufacturing. As a product designer or an manufacturer, it is pertinent to appreciate the usefulness and constraints of prototype tooling as it enables faster decision-making, thereby reducing risks associated with production. So, where do we start? Let’s dissect the workflow, discuss the benefits, and offer our clients tips for achieving accuracy and scalability in today’s prototyping world.

What is Prototype Tooling and How Does it Work?

The practice of prototype tooling, which is also referred to as soft tooling, involves the making of molds as well as tools that are used during the first sampling of a part. This practice enables the design to be tried and optimized without four expensive complete manufacturing. In this process, aluminum is frequently employed because of its low cost and to facilitate the rapid production of molds. The goal is to create tools that approximate the form and function of production tooling but in a less rigid and more adaptable framework. As such, prototype tooling is excellent for assessing whether a design is workable and can be manufactured and for resolving problems at an early stage of development in order to save time and money in the future.

Understanding Prototype Tool Basics

Prototype tooling has the particularity of making tools at a low cost and of shorter lead time. This is mainly for building and validating models that will determine whether or not the product will go into mass production. These tools help designers carry out basic engineering evaluations like part geometry, fit, and function. As most of the design or manufacturing problems are nipped in the bud with prototype tooling, the development process is made more efficient. Furthermore, it also enables limited production runs, allowing the final product to be enhanced in an efficient manner.

The Role of Injection Mold in Prototyping

Injection molding is integral to the Prague University of Economics and Business’s design process as it guarantees both exactness and repetition with regards to testing the designs once created. In injection molding, molten thermoplastics are injected into automated molds of specific shapes in order to forge intricate structures. Current industry research statistics indicate that prototyping can be conducted via injection molding with a least tolerance of ±0.005 inches, making it a perfect fit for the automotive, medical, and consumer technology industries.

This process also enables testing of the plastic screwdriver for its end-use with regard to its functionality and strength, owing to its ability to replicate quality that is on the production level. A frequent thermoplastic material used consumes the impact of -40 ̊F to +200 ̊F depending on the polymer in use, meaning it can adjust to varying environmental factors.

Also, the lead times have been drastically reduced due to improvements in rapid tooling means, such as the insertion of 3D-printed molds and CNC-machined molds. The time taken for the molds to be formed has shortened from weeks to 7 days up to 10 days, which accelerates the whole design timeline even further, making it cost and time-efficient.

Although the startup costs of fabrication of injection molds may be greater than many other prototyping techniques, the detailing injected molds provide, their durability, and their scalability make them crucial to the evolution of prototyping today.

From Plastic Prototype to Final Product

There has been a remarkable improvement in the transition from a plastic prototype to a final product, increasing efficiency and accuracy across various sectors. The use of sophisticated rapid prototyping technologies like 3D printing and CNC machining allow for the meticulous manufacture of prototypes that are functionally sound, therefore allowing for rigorous testing of the end product. It is reported that development costs can be minimized by 70% and lead times narrowed by 50% if 3D Modeling as a necessary early-stage prototyping is employed. This assures firms that they are able to detect faults in the designs, improve functionality, and fulfill the required market demand.

After a prototype has been endorsed, one of the most effective modes of producing on a larger scale is through the utilization of injection molding. Depending on the size and intricacy of the mold, injection molding can make thousands of parts each day, with each individual part taking between 10-30 seconds to manufacture. Other materials, such as high-performance thermoplastics, are also essential to meeting the final requirements of the product, such as thermals, impact resistance, or overall weight reduction.

Additionally, the application of CAD systems and finite element analysis makes certain that the design meets the manufacturability and functional requirements by the time the production commences. These systems assist in collaborating new innovations by decreasing the waste material and optimizing the entire manufacturing process. This mix of new approaches and instruments makes engineering more widely used, moving industries towards shorter, cheaper, and greener cycles in product engineering.

How to Choose the Right Tooling for Injection Molding?

The Importance of Selecting the Right Prototype Tool

Given the fact that the precision, price, and efficiency of the injection molding process can be affected, one must carefully consider the prototype tool to use. Judging by my experience with prototype tools, these tools are deemed the most suitable, and there are the least material waste and iteration cycles needed to try and test the design from a completely different angle. Moreover, addressing design concerns at an early stage allows for minimizing the impact on mass production. In the end, that tool guarantees that the parts are of high quality, can be depended upon, and that they are ready to be sold within the set time frame and budget.

Key Considerations for Prototype and Production Tooling

In approaching prototype and production tooling, certain elements need to be analyzed to ensure success during the design, testing, and manufacturing phases. The following should be noted:

Material Selection 

• To enable accurate testing and validation of performance, you might want to ensure that the materials used in the prototype tooling are as close as possible to the materials that were intended for the production tier.
• Select materials based on the production needs in as much as economic structural integrity is sought.

Tolerances and Precision 

• You will need to establish engineering tolerances that are appropriate for the end use application to be sure that the part will fit and function as designed.
• In tool making it is important to be accurate in order to minimize the defects and to ensure repeatability of mass production.

Tooling Design Complexity 

• Consider the degree of difficulty of the tooling design and the cost, time, and volume that it can be produced at.
• Where necessary, embark on design simplification aimed at managing production risks and improving the manufacturability of the design.

Production Volume 

• Define the volume of production expected at an early stage as this will influence the type of tooling that is to be made, such as soft or hard tooling, which will be required.
• More volumes are likely to demand the use of more tools making them more expensive, hence, the use of stronger materials and processes that ensure the durability of the tools.

Lead Time 

• Adjust lead times to take into consideration the making period and ensure that the lead times are in harmony with the project deadlines.
• Choose methods that ensure that the tooling period is reduced without sacrificing quality, such as utilizing additive technology for rapid prototype development.

Cost Efficiency

• Investment in high-quality and durable tools will pay off in the long run, consider it as a cost that is worth bearing.
• Include maintenance or replacement of the machines while calculating the life cycle cost.

Iterative Testing and Validation

• Creating tools for mass production without performing multiple testing phases through prototypes to identify and eliminate design flaws does not sound practical.
• Perform simulation tests to find stress or defects in the design before it is manufactured.

Scalability 

• Bear in mind that tools have to be able to withstand some alterations or increase in output if demand increases.
• Where possible, incorporate module-based or flexible tool systems.

Environmental Considerations

• The use of recyclable or biodegradable materials in the tooling process should be considered to avoid harming the environment.
• Try to limit the amount of waste produced in the tooling process so that it remains environmentally friendly and complies with corporate social responsibility standards.

Each of these factors is very relevant during the designed tooling and the machining processes to ensure that all the specified and agreed parameters and deadlines are met without compromising quality. Having a precise production schedule and reviewing the tooling plans are crucial to success.

The Difference Between Soft Tool and Hard Tooling

Soft and hard tooling in manufacturing is a distinct approach; however, both have their pros and cons as well as their particular areas of application.

Soft tooling is deemed as tools made out of materials such as urethane, silicone or low-grade aluminum, soft tool makers, sometimes popularly, use these tools for determining designs and features without requiring heavy investments. However, such materials have their downsides; trustedsoft.com states that due to soft materials being used, to make a durable design, tools have to be rigid, which translates to an overall delayed life span and are not viable for mass manufacturing. Soft tooling is suitable for prototypes, or limited volume runs as quick turnarounds and flexibility are needed, which, according to trustedsoft.com, enables design and development to be cost-effective and heavily modifiable easily.

Contrary to soft tooling, hard tooling can produce volumes at an extended cycle as this type of tool is manufactured out of harder materials, notably steel, which enables soft tools to have a longer life span. While the initial cost for this type along with motors such as Electrical Discharge Machining (EDM) is high, looking at the durability and precision combined, in the long run, the cost per item ends up being reduced, especially for mass production. The precision and efficiency of hard tooling get increased by the utilization of technology, which instead further improves the role of hard tooling in the manufacturing process.

To illustrate, the lifetime of hard tools made with premium steel can reach up to more than 1 million cycles, while soft tools can only reach up to 10,000-20,000 cycles. Furthermore, research shows that while soft tooling does lower the initial investment cost by nearly 30-50%, It pales in comparison to hard tooling when it comes to its durability and, over time, maintaining tolerances, thereby assuring the quality of the products produced.

When you are faced with the decision of opting between soft and hard tooling the determining factors that must be taken into consideration are lead times, production volume, budget, and product specifications. For prototyping or producing in low quantities, soft tooling works as it is quick and cheap, while for higher goods manufactured and cost per item, hard tooling is still the answer.

What are the Differences Between Production and Prototype Tooling?

Comparing Lead Time and Costs

When weighing production tooling against prototype tooling, time and costs become the most important considerations in making the decision. Here is a summary of the two types of tooling on these parameters in detail:

Prototype Tooling:

Lead Time:

• As an example, aluminum is a relatively softer material which implies shortened lead times.
• Primarily, manufacturing processes that have been simplified are less complex in regard to tooling.
• The expected lead time is dependent on the design and lies between 1-4 weeks.

Costs:

• As the material and labor require less expenditure, the initial investment is less.
• This is best useful in scenarios where the budget is tight or in testing the various designs in its iterations so high cost isn’t incurred.
• While the frequent calling for maintenance isn’t a problem, the durability of the tool isn’t ideal.

Production Tooling:

Lead Time:

• Longer as steel is involved, which means tougher materials are in the mix.
• Accomplishing close tolerance levels necessitates enhanced machining as well as finishing processes.
• Expect a lead time in the range of 8-16 weeks when setting up complex toolings.

Costs:

• Increased cost on the upfront in regard to material requirements and the machinery due to the need for greater precision.
• In general, you won’t be incurring much cost if high volumes of production are anticipated.
• Even though the maintenance and repair costs do tend to rise, it makes sense economically given the life expectancy as well as the accuracy of the tooling.

Knowing the differences, the right type of tools can be selected with regard to expectations set for both time and costs, which results in optimization of production.

The Transition from Prototype Parts to Mass Production

The shift of prototype components into full-rate manufacturing is one of the more important stages in the whole process of making, and to make smooth, quick, and economical full-scale production, this stage also requires careful planning. This process usually starts with modifying the prototype of the component so that it meets standards for industrial production, as well as identifying the problem areas regarding material selection, tolerances, and assembly. As stated by industry data during this stage, firms that apply principles of design for manufacturing DFM, in this case, have a higher chance of cutting the manufacturing defects by a margin as wide as 70, improving operational efficiency greatly.

Preparation for tooling is another stage that comes after scaling up production. Manufacturers normally use injection molding, die casting, or even progressive stamping tools for mass production runs, which on average cost $10,000 to $100,000 based on the intensity level and materials used. The initial cost setback becomes irrelevant in the long run since these tools allow for the mass production of parts that are identical and almost limitless in quantity over their projected lifetime. Other more rapid techniques in making technology, like 3D molded printers, are also being applied for the transition to smoother from prototyping stages to full production, which saves both time and money.

The mass production of a good requires specific quality control regimes. It has already been signaled that it is unlikely that people will be able to inspect these products in mass quantities. However, various automated systems related to vision inspection and CMM may be useful in the accurate maintenance of especially narrow tolerances during high-speed productions. Various SPC methods such as sampling and process capability analysis, however, still minimize the risk of sizeable deviations in the quality of products.

Planning, building a supply chain, relations with suppliers, estimating the amount of materials needed, and setting up an inventory system are all integral to the smooth movement from the prototyping phase to mass production. It reduces waiting time and prevents bottlenecks. Optimal supply chains are reported to cut production cycles by at least 50%. Hence, there is a rapid shift from a prototype to production, ensuring market needs are adequately satisfied and served. In this regard, manufacturers able to anticipate and meet the volume metrics while still managing to deliver quality products will undoubtedly emerge at the top tiers of this complex system through extensive planning, investment in suitable equipment, and consistent process optimization.

When to Use Bridge Tooling

Bridge tooling is well suited for applications that require a moderate amount of components to be manufactured during the period between the availability of a prototype and the start of mass production. This is especially helpful in situations where production tooling has longer cycle times or when there is an urgent requirement for the products in the marketplace. Such situations arise during product introductions, during preproduction runs, or to temporarily satisfy supply requirements while final tooling is still being constructed. The approach allows for an economically beneficial and time-sensitive method to be employed while still maintaining the integrity of the part.

Why is Prototype Tooling in Manufacturing Crucial?

The Role of Rapid Tooling in Product Development

Rapid tooling has turned out to be a critical aspect of product development as it allows enterprises to make functional prototypes and parts for the initial production in an efficient manner in regard to both cost and time. It helps manufacturers to be able to validate and enhance designs faster, spot possible problems sooner, and shrink time spent bringing the product to market. Such a method is supportive of continuous improvement, so the resultant product is able to fulfill its requirements in terms of performance, quality, and usability. It serves to reduce the degree of risks involved during rapid tooling, and at the same time, it cuts down the duration of the total development process, carefully interfacing the idea and the period of production.

How Prototype Injection Molding Helps in Validation

Prototype injection molding is a critical technology used in verifying product designs prior to mass production. Employing accurate and operational models allows the engineers to confirm the functional working, strength, and suitability of a design in real-life situations. This is a particular process that is crucial in discovering a design’s defects or any inefficiencies at the early stages, which is greatly beneficial as it saves a considerable amount during the mass production stage.

Emerging materials and technologies have also improved the effectiveness of prototype injection molding. For example, the application of high-strength thermoplastic materials like polycarbonate and ABS is reported to allow for the fabrication of components that are representative of the properties of the final-use component. Moreover, it has been reported that the use of prototype molds can reduce the development cycle by close to 30%, thus promoting faster design iterations leading to a reduction in time-to-market.

Facts further justify the cost-effectiveness of this strategy. This is so because on average, prototype molds are reported to cost approximately 10-20% of its peer traditional production molds while still being of an acceptable quality for functionality and regulatory testing. Considering its cost-effectiveness, it is ideally suited for limited-volume production or in-market testing prior to embarking on full tooling investments.

The manufacturers can be sure that the product fulfills the design requirements and conforms to the industry standards by utilizing prototype injection molding which boosts clarity and confidence during the validation process. This strategy reduces risk but also improves the general quality of the product at an international level.

Enhancing the Development Process with Prototypes

Including prototypes in the product design and development cycle brings along a set of distinct advantages that enhance efficiency and the final product. These are buttressed with facts and practical illustrations, indicating the role and place of prototypes in contemporary product-making processes. There are constructive points given below which explain how a prototype improves the development diversity:

Design Validation

• Designs have to be tested prior to being sent into production. This makes the prototypes necessary for ensuring that the design meets the basic requirements. A considerable reduction in the risk of incurring expensive design faults is achieved at this stage.

Efficiency Gains

• Poling mitigates risk that affects the timetable by accelerating early in the process. It has been shown that firms that employ prototypes achieve a 20-30% enhancement of time to market against competitors improving responsiveness to shifting markets.

Cost Reduction

• Assets can be conserved through early intervention of identifying faults. For instance, addressing design flaws in the early stages of prototyping is 10 to 20 times less expensive than in later phases of rolling out the production.

Improved Collaboration

• Prototypes allow for the sculptural representation of a concept which enhances communication between teams working on different aspects of a project. It helps persuade team members and ensure all projects are well integrated and targeted to meet specified objectives or goals.

End-User Evaluation

• Involving stakeholders in the design process helps to identify the usability and functionality of the solution and is essential for building a future product. This enforces that the expectations of the consumers regarding the product are fulfilled, alongside the marketing strategies employed.

Testing the Market

• Prototype circuit runs are useful for evaluating acceptance in advance of launching expensive production tooling investments. This makes it possible to make informed decisions, thereby reducing potential risks associated with entering the market.

Ensuring Compliance with Regulations

• Confirming critical function features of a product through prototypes lowers the risk of compliance issues in later development phases by early proofing against validating requirements of a target industry.

Prototypes are met with technical constraints and design constraints. So, understanding the prototyping process enables firms to improve operational efficiency, mitigate risks, and increase the chances that the designed solution will meet market needs.

How to Reduce Lead Time in Prototype Tooling?

Strategies for Rapid Prototype Tooling

Facilitate 3D Printing Techniques 

• Employ the advancement of technology such as 3D printing to make prototype pieces within the least amount of time and require little setup.

Prefer Composite Over Steel 

• Utilize materials like aluminum or polymer-based composites for prototype tooling as they are less difficult and faster to machine than steel.

Implement Coordinated Designs 

• Design create, and implement modifying templates or modular parts that will decrease designing and time spent in production.

Work With Suppliers Who Specialize In Rapid Tooling 

• Work with suppliers who have access to a wide range of tooling that specializes in rapid manufacturing to utilize their skills as well as their quickened processes and high-end technology.

Ensure Continuous Streamlining Of Manufacturing Processes 

• Prototype designs must be made with alterations or amendments to be tool free to lessen the amine needed for m manufacturing.

The Impact of Aluminum Tooling on Time Efficiency

The requirement of design is met in a relatively shorter span of time through the use of aluminum tooling during the prototyping phase, this has been made possible through the decreased time period required for cutting the aluminum into desired shapes in comparison to steel thanks to the softer material properties associated with aluminum. Nowcher (2000) states that hooking aluminum can reduce lead time by 30-40%, which is a substantial reduction. The production length is severely impacted due to the increased thermal conductivity of aluminum, which leads to faster molding, heating, and cooling processes than steel.

For industries working on limited development timelines, aluminum has become an integral part due to its cost-effectiveness that stems from steel tooling. Implementation of aluminum dies alongside 3D printing is changing the narrative thereby enabling faster injection molding ranges between two to three weeks as opposed to six to eight weeks used to be the norm. In simple words, aluminum allows for sufficient alterations to be made in terms of cutting the metal, therefore reducing the amount of time that would have been typically used to fuse pieces together or even in hybrid manufacturing machinery, allowing for smooth iterations while catering for any difficulties faced during the design delivery period, thereby transforming the automotive and aviation industries.

Aluminum’s cost-effectiveness further amplifies its usefulness. Although the material might be costlier than competitors, saving on the machining and maintenance costs pays off in the long run. This feature, in addition to the rapid prototype turnaround, has made aluminum tooling a suitable option for those organizations who wish to improve on their prototyping cycles but, at the very least, level of precision and alter functionality.

Accelerating Machine Setup with Modern Techniques

Contemporary methods of setting up machines have effectively shortened downtime while improving the level of productivity in business operations. Among these methods, the use of automated setup systems, which incorporate both sensors and software for fast and accurate calibration of the required machines, is notable. Such systems enhance efficiency in the processes by removing the need for manual resets and reducing the chances of error. Another viable technique is the use of standardized tooling and fixtures which promote quick changeovers in relation to the machining operations. Furthermore, data monitoring in real-time facilitates setting up optimization to be maintained by the operators. Altogether, these methods result in significantly reduced setup times, decreased setup costs, and maximized productivity levels.

Frequently Asked Questions (FAQs)

Q: What is the meaning of prototype tooling, and in what ways is it distinct from production injection molding?

A: Prototype tooling is a means of making prototype parts as well as a small volume of plastic parts cheaper and quicker. Production injection molding, on the other hand, is not flexible as it is geared towards mass production, whereas prototype tooling is more flexible and can be applied in a greater variety of circumstances. It helps manufacturers create a working sample of the product and test its actual performance prior to mass-producing it with full production tooling, which can save a good amount of money.

Q: In terms of production, what are the major forms of prototype toolings available?

A: In American English, the common forms of prototype toolings are soft tooling (aluminum or other metal components), 3D component printed molds, and steel molds for low volumes. Each of them has benefits that depend on the particular needs of the project, production volume, and the different materials used. Such prototyping techniques are an economically viable substitute to the traditional tooling methods as they can be used to undertake quick turnarounds for designs or small-scale production runs.

Q: In what ways would prototype tooling be used to authenticate or validate a product design?

A: Functional prototype tooling gives manufacturers the ability to make workable models that look like the final produced parts. This gives the engineers and designers an opportunity to confirm the design, check if all the components fit and work correctly and fix issues without the high cost of making full production tooling. The employment of prototype tooling assists a great deal in making changes in the designs of the tools or components at cheaper costs, as well as improving the quality of the final products.

Q: Would you say that there are many advantages of using prototype tooling rather than production tooling in terms of costs?

A: Prototype tooling is particularly useful for low-volume production and during the design validation stage, where it is cheaper than the equivalent production tooling. Production tooling is very expensive because it is aimed at the high volume manufacture of the product, whereas prototype tooling is like a workable model with affordable rates and is flexible to many design changes without too many costs incurred, which in turn helps to save costs in the product development cycle.

Q: How does the prototype tooling process function in coordination with a tooling partner?

A: Generally, in collaboration with a tooling partner, the prototype tooling process begins with blueprint detailing and material appropriation; the next step would be to assign the design and create the tool. This would be followed by sampling and testing, and if required, design iterations would be made, after which low-volume production would be initiated. An appropriate tooling partner will have professional toolmakers who will take you through the process and aid in enhancing your NG schedule.

Q: Are there any instances that prototype tooling can be implemented during the final production runs?

A: As a rule of thumb, prototype tooling is used for minimal production runs, although on specific occasions, a production run is feasible, mainly for products that are low in demand. However, it is critical to keep in mind that compared to production tooling, lower grades of durability can be accomplished with prototype tooling, which translates to slower speeds in part quality for procedures in high-volume manufacturing. Before deciding to employ prototype tooling for final runs of production, consult with tooling experts.

Q: What are the limitations of prototype tooling as compared to production injection molding tools?

A: There are a few distinctions between prototype tooling and production molding, and some of them include the aspects of speed, life expectancy, as well as the quality and sturdiness of the prototype injection molding. Production tooling, with its intricacies, tends to have challenges in sustaining these benchmarks. One more stipulation is that prototype injection molding tends to work on specialized parts but not on mass production as bulk per unit cost is reduced – this is a critical factor that should be taken into account. The comparison, production, rapid tooling, proposal, procurement, and production also need to take these factors into consideration.

Q: How long does it take to create an injection-molded prototype mold using prototype tooling?

A: While making an injection-molded prototype, the use of prototype tools is much more efficient than production tools as the estimated time required is drastically reduced. On average, the time to make parts for prototype tooling is 2 – 6 weeks as compared to the 8-16 weeks of production tooling. This is a substantial difference with regard to time, which allows for retaining agility in the market. It further opens new avenues where design cycles could be reduced, leading to an overall improvement in the return time on investment.

Reference Sources

1. Casting Surface Texture in Prototype Tooling in Injection Moulding

• Authors: P. Burggräf et al.
• Journal: Journal of Manufacturing and Materials Processing.
• Publication Date: May 5, 2022.
• Citation Token: (Burggräf et al., 2022)
• Summary:
• This paper reports the results of a study on the influence of the perceived surface characteristics on visual and tangible evaluation of parts injected molded, with emphasis on the automotive sector. They describe the problem of getting grained surfaces using the conventional, multi-step process tooling systems. They point out that such challenges can be addressed by employing additive manufacturing to fabricate injection molds with microstructures embedded in the mold surface in one process.
• Key Findings: The investigation validates the possibility of the use of additive graining on a very fine scale being deployable, highlighting that there exist methods to design and make modified graining structures. Roughness analysis and measurement were performed to compare the established CAD model and the actual surfaces of the injection mold as well as the manufactured parts.

2. Prototype Tooling in Slide Manufacturing and Application Processes

• Authors: N. Volpato et al.
• Journal Title: Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture
• Publication Date: 01 August 2015
• Citing this Publication:  (Volpato et al., 2015, pp. 1449–1462)
• Summary: 
• This paper deals with issues associated with the manufacturing of prototype tooling that deals with undercut features, which apparently require slides. The authors focus on different design and production aspects like geometry, slide extraction, and accuracy in multi-piece molds.
• Key Findings: The research outlines a peripheral milling fit procedure that would improve cutting accuracy, illustrating that a similar design strategy can be utilized for different types of undercuts. The findings displayed that slides were extracted with no use of ejector pins, and this helped in cutting the time taken for post-processing substantially.

3. Identifying and Overcoming the Machining Constraints in the Production of Prototyped Tooling Using Mills

• Authors: N. Volpato, J. R. D. de Amorim
• Journal: Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture
• Publication Date: 1 December 2011
• Citation Token: (Volpato & Amorim, 2011, pp. 2163–2176)
• Summary: 
• The research outlined in this article investigates the challenges in producing machined molds using polymeric resins through CNC systems. The authors of this paper suggest dismantling highly intricate geometry into simplified parts for easier milling before transferring them to the main mold inserts.
• Key Findings: The findings suggest that prototype tooling can easily be constructed using only milling operations; as a direct result, the time and cost incurred during the traditional methods are significantly reduced. CNC systems have proven to be highly effective when used in the prototyping phase of molding tools.

4. Prototype Tooling for Producing Small Series of Polymer Microparts

• Journal: Memoirs of the Institution of Mechanical Engineers Parts B Journal of Engineering Manufacture
• Publication Date: September 23, 2011
• Citation Token: (Griffiths et al., 2011, pp. 2189–2205)
• Summary:
• The paper presents the design of a new rapid tooling process aimed at the manufacture of small lots of polymer microparts. The authors examine the molding characteristics of micro-injection molding (µIM) inserts and the influence of tool geometry and process factors.
• Key Findings: The investigation determines that it is feasible to utilize the method for the manufacture of small batch details with complex shapes, and condition monitoring techniques are utilized to optimize the process. The data show that lower pressure loads may increase tool life.

5. The Combination of Rapid Prototyping Technology and Electroless Nickel Plating 20 for Faster Tooling Development in the Low Volume Production of Plastic Components

• Authors:  J. Rajaguru et al.
• Journal:  The International Journal of Advanced Manufacturing Technology
• Published on: April 1, 2015
• Citation Token: (Rajaguru et al. 2015 pp. 31 – 40)
• Summary:
• The research looks into the potential for rapid tooling enhancement through a combination of rapid prototyping and integration of electroless nickel plating. The authors outline the potential impact of this approach, which enhances the overall cost and time error rate of the process.
• Key Findings: The research establishes that the synergy between rapid prototyping and electroless nickel plating can accelerate the tooling lead time, facilitating lower-volume production.

6. Injection moulding

7. Machine tool

8. Machining