Revolutionizing Low-Volume Manufacturing
Breaking the Steel Mold Paradigm
Traditional tooling creates unsustainable bottlenecks for pilot runs and bridge production:
- 25k−150k tooling investments freezing capital
- 14-22 week delays to market launch
- ±0.003" tolerance barriers for complex geometries
Our rapid tooling hybrid approach eliminates these constraints:
Industry-Specific Solutions
1. Medical Device Manufacturing
- Problem: $95k tooling for low-volume medical device tooling with ISO 13485 compliance
- Solution:
- Hardened aluminum cores with <0.0002" tolerances
- Micro-molding capability for 0.1mm features
- 3,000 biocompatible parts in 19 days | 63% cost reduction
2. Automotive Prototyping
- Problem: 18-week waits for automotive prototype molds
- Solution:
- Modular insert systems for sensor housings
- Gas-assist technology for hollow structures
- 500 functional prototypes: 17 days | $8.7k all-in
3. Consumer Electronics
- Problem: $45k minimum for overmolding tooling with IP67 seals
- Solution:
- Quick-change cavities for multi-material trials
- LSR/TPE encapsulation of PCBs
- 10k units: 23 days | 70% less than steel tools
Precision Engineering Matrix
| Application | Tooling Technology | Tolerance | Optimal Volume |
|---|---|---|---|
| Thin-wall housings | High-pressure tooling | ±0.002" | 1k-50k |
| Metal/plastic hybrids | Vertical overmolding | ±0.0015" | 500-15k |
| Optical components | Mirror-finish EDM | <0.02μm Ra | 5k-100k |
| Under 7-day turnaround | Express aluminum tooling | ±0.003" | 500-3k |
Cost-Control Technologies
1. Conformal Cooling Revolution
- 3D-printed channels following contour geometry
- Results:Cycle Time↓42%Warpage↓78%Energy Use↓31%
2. Hybrid Tool Systems
- Steel frames with aluminum cavities
- Cost Impact:
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+ 65% cost reduction vs. hardened steel + 50% faster machining
3. Bridge Tooling Program
- Dedicated to <5 week lead time projects
- Transparent Pricing:
- $4,200 tooling fee
- $0.22/part (MOQ 500)