Tooling
Before manufacturing begins, we simulate the injection molding to detect any potential flaws and construction risks early on. Then the tool is designed, and you receive access to trial samples and protocols.
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Explore the possibilities
The tools are tailored precisely to your requirements. This can include various types of inlets, such as edge, rod, snout, tunnel, film, or hot runner. The tool surfaces can be grinded, polished, blasted, spark-eroded, or etched to achieve the perfect texture for your injection-molded parts. We also offer overmolding tools and true 2K tools when the components need to consist of different materials.
Finally, the tools are assembled, and a test run is conducted to ensure their correctness. Afterward, the trial injection molding in our injection molding machines can commence.
Prototype tools - aluminum
Tool design is simplified as much as possible to meet the number of components to be manufactured. Manufacturing takes place internally within the group, and the tools are made of aluminum, ensuring a fast and efficient production process and keeping investment costs as low as possible. In the tool, components can then be injection-molded under production-realistic conditions. Typically, around 100 components are manufactured.
Low-volume tools - Aluminium
The tool design is adapted for a more automated injection molding process. Manufacturing is carried out internally within the group, and the tools are made of aluminum, ensuring a fast and efficient production process and keeping investment costs as low as possible. In the tool, components can then be injection-molded under production-realistic conditions. The tool's lifespan is up to 100,000 shots, which covers the lifespan of a significant number of components.
High-volume tools - Steel
The tools are made of steel and are purchased from external tool suppliers. At each step of the process, our project team monitors schedules to ensure smooth operation from start to finish. This includes everything from tool design approval to the measurement of trial samples and tool adjustments. Efficient management is ensured by conducting all manufacturing in accordance with our tooling standards. Our project team then handles the retrieval of tools for the production of final trial samples at our own site.
FAQs
The main difference between aluminum tools and steel tools lies in their tool lifespan. Aluminum tools are lighter and can be machined faster in our milling machines, often offering cost advantages. They are ideal for producing prototypes and small volumes. Aluminum also has good heat conductivity, allowing for more even temperature distribution in the mold. The downside of aluminum is that it's a softer material and wears out more quickly, especially with glass-fiber-filled materials.
Steel tools have higher durability and resistance to wear. They are ideal for large-volume production and for injection molding with materials containing a high level of glass fiber or high-temperature materials. Steel tools can withstand higher pressures and temperatures during the injection molding process and have a longer lifespan compared to aluminum tools. The downside of steel tools is that they take longer to manufacture, often come with a higher cost, and are larger and heavier.
The choice between aluminum tools and steel tools depends on specific needs and requirements for the manufacturing process. If the volume is low, and the lead time is short, aluminum tools can be a suitable choice.
On the other hand, if high volume and durability are crucial, steel tools are typically the preferred option.
Do you need assistance or guidance in choosing the type of tool you require? We can help! At Prototal, we have extensive experience with tools and are happy to guide you to the right choice.
- ANALYSIS
To ensure the quality of our process, we always simulate the injection molding. By doing so, we can detect potential issues and risks with the design early on. Any necessary adjustments are made, followed by a new simulation. Thanks to this, we can reduce the number of adjustments and offer a more cost-effective production. - DESIGN
Our in-house tool designers create the aluminum tools. Depending on your requirements, the design is customized for the most cost-effective manufacturing.For steel tools, our tool supplier designs the tools according to our specifications, subject to our approval.
- MANUFACTURING
Milling and spark erosion of the tools. Automated preparation and pick robots supply machines with materials, ensuring efficient production. - ASSEMBLY
The tools are completed and assembled. This is also where the blasted, grinded, or polished surfaces that give the final product its finish are created. Before injection molding, we conduct a test run of the tool to ensure its correctness. - VERIFICATION
The tool undergoes an injection molding test to produce trial samples. Verification of injection parameters and compliance with the customer's specifications is carried out to ensure that the requirements are met. Documentation, such as measurement protocols and PPAP, is provided as agreed with the customer.
- The choice of material affects the shrinkage compensation that must be made by the tool.
- The choice of material can impact the tool's lifespan.
- If we get involved early in the project, we can assist with product reviews to make the component more suitable for quality-assured manufacturing.
- The number of components to be manufactured influences the tooling solution. Is it for prototypes, low volumes, or high volumes?
- The number of mold cavities? More mold cavities result in a higher tooling cost but a lower component cost.
- The tool's complexity is determined, for example, by the presence of many ribs on the component.
- The tool's complexity is determined by whether undercuts are required in the tool.
- Are there any encapsulated components?
- What should be the surface finishes in the tool? Milled, ground, polished, blasted, spark-eroded, etched.
- Can there be a visible gating point?
