What is Rapid Tooling? Overview, Advantages & Limitations

Testing and validation of parts is an essential part of the product development process. Although other prototyping options such as 3D printing, CNC or vacuum casting generally allow for faster and cheaper prototypes, the main advantage of rapid tooling lies in its process and materials. For this reason, Rapid Injection Moulding is still one of the most common forms of rapid tooling today. In this article, we take an in-depth look into the process, how it works, when to use it, and how it compares to other rapid prototyping methods.

What is rapid tooling in injection moulding?

Rapid tooling (RT) refers to the process of rapidly producing moulds (also known as tools) for use in the injection moulding process. Traditionally, creating moulds for injection moulding could be a very time-consuming and expensive ordeal. With RT, engineers and designers can manufacture moulds in a significantly shorter timeframe and at a lower cost than a full production mould tool, all without compromising the quality of the part; rapid tooling allows for the fabrication of detailed and complex geometries with precise tolerances using production-grade materials.

By eliminating the need to remake a full-scale production tool, the speed and lower costs of rapid tooling offer greater flexibility and provide designers and engineers the opportunity for innovation. This makes the process suitable for not just lower volume production but also market testing and rapid prototyping applications.

How rapid tooling works

How are rapid tools made and how does it differ from conventional tool making? There are many different approaches depending on the part and requirements, but essentially the general idea is to reduce as much as possible both the time taken and the costs involved in manufacturing the tool. Some of the most common techniques include:

• Opting for Aluminium or Softer Steels: Aluminium or soft steels are much easier to machine, which helps expedite the machining process. They are also cheaper than hard steel materials.
• Using Standard Mould Bases: Utilizing ready-made or standardised mould bases and focusing on producing inserts can save several days of time in the tool-making process.
• Eliminating Extra Processes: Omitting supplementary steps such as Electrical Discharge Machining (EDM) can enhance efficiency.
• Post-Machining Features: Incorporating features or threads after the initial machining rather than including them in the initial tooling process facilitates quicker production.
• Abandoning Side Actions: While abandoning side actions may increase cycle time, it can still prove beneficial in cases where quantities are low.

Reasons to use rapid tooling for your project

Here are the top reasons why you may want to consider the process for your next project:

1. Prototyping in the Production Intent Material

In certain instances, prototyping in production intent material is a 'must have.' This may be because standard prototyping options cannot achieve the temperature or other environmental requirements, or you want a clearer picture of how the parts will perform in real-world applications. If so, prototyping in production intent material will allow you to test and confirm that you’ve made the correct material choices.

2. You Only Require Lower Volumes

Unlike full-scale production tooling, rapid tooling is designed to cater to 'smaller projects.' This allows for the fabrication of production-grade parts with precise tolerances but in lower volumes. This is especially beneficial for aerospace components or specialist vehicle manufacturing that deal with smaller quantities of parts but require high-performance materials.

3. You Need to Get Your Product to Market Quickly

Rapid tooling shortens the time between the initial idea and evaluation. This fast turnaround can help companies obtain a competitive edge by bringing new products to market more rapidly. In other words, you can get parts to market in a fraction of the time compared to traditional methods, which is vital if you’re working with a tight timeline.

Limitations of rapid tooling

While rapid tooling in injection moulding offers many benefits, like any other process, it isn’t without its limitations. So, how does RT compare to conventional tooling methods and other rapid manufacturing technologies like 3D printing and CNC machining? Here are some of its main disadvantages:

• Shorter Mould Life Cycles: Aluminium and softer steel tools do not last as long as steel moulds due to the stress placed on them by the high-pressure injection process. This means you won’t be able to get as many runs from it.
• Not Suitable for Early-Stage Prototypes: If you’re at the outset of prototyping and anticipate the need for multiple modifications or significant changes, avoid rapid tooling. This is because the process is costly and less tolerant of design changes.
• Can Be a Costly Process: While rapid tooling processes can be cost-effective, they can also be expensive, especially for low-volume production runs. The initial investment in tooling may not be justified if the production quantity is not sufficiently high.

How to Get Started With Rapid Tooling

Are you trying to source a rapid tool manufacturer for your project? Essentially, you need to be very clear on what exactly you are after. The increased speed and lower costs of rapid tooling compared to conventional production tooling will impact the final parts, but as long as you know what you are looking for and clearly communicate your requirements to the manufacturer, you should be able to avoid surprises.