Prototype Tooling: Techniques, Benefits, and Applications
What is prototype tooling? How can it help optimize product development? Learn about the different techniques to choose the right one for your project.
Prototype Tooling: Overview
What is Prototype Tooling?
Prototype tooling, also known as soft tooling or rapid tooling, is a process used to create tools for manufacturing prototypes. This may include molds, dies, jigs, fixtures, and other necessary components.
By creating physical prototypes that are functional and accurate to the final design, manufacturers can evaluate the performance of these tools and identify potential issues. Then, they can make necessary adjustments to the design before investing in the full-scale production.
The techniques used for prototype tooling can be categorized into two primary types: direct prototype tooling and indirect prototype tooling. Direct methods involve shaping the material directly according to the prototype design. On the other hand, indirect methods require creating a master mold or pattern that will be used to produce the prototype. We will delve deeper into the details of each method later in this article.
How Does Prototype Tooling Differ from Production Tooling?
Prototype tooling and production tooling serve distinct purposes within the product development process. Prototype tooling is primarily used for testing and validating designs, while production tooling is made to manufacture the final product. They also differ in materials, durability, design accuracy, and costs.
Prototype tooling often employs softer materials like aluminum or mild steel, which are easier to machine and modify. This makes the prototype tooling relatively less durable, which is fine since it is only used in low-volume production to create a limited number of samples for evaluation. Additionally, though there is a focus on accuracy, the design of prototype tooling may be less precise than production tooling due to the simplified manufacturing processes. which also results in lower tooling costs.
In contrast, production tooling is engineered for high-volume production, so it typically utilizes harder metals or other durable materials that can withstand the rigors of continuous use in a manufacturing environment. Production tooling also requires more automated systems to replicate high-precision designs. While this often leads to higher costs per unit, it is essential to ensure consistent product quality that meets stringent specifications.
Direct Prototype Tooling Production Techniques
Without the need for an intermediate mold or pattern, direct prototype tooling techniques can either be subtractive or additive. Subtractive techniques focus on removing material from a solid block to carve out the prototype tool. Conversely, additive techniques such as building up the prototype tool layer by layer, adding material to create the desired shape.
Common direct prototype tooling techniques include:
CNC Machining
CNC machining is a subtractive technique that leverages computer-aided design (CAD) and automated machinery to create prototype tools. With computerized controls, CNC machines can rapidly produce prototypes with high accuracy and detail.
This technique is highly versatile, so it can be used to create both simple and intricate prototype tools using various materials, from metals to plastic, and wood. The automated systems also offer greater repeatability, ensuring that prototypes consistently meet the exact specifications.
However, it is important to note that CNC machining requires technical expertise to design CAD files, generate CAM files, and operate the CNC machine. This can add to the overall cost of the prototyping tooling process.
Image Source: Freepik
Fused Deposition Modeling 3D Printing
Fused Deposition Modeling (FDM) 3D printing is an additive prototype tooling process that involves extruding heated filaments to build up layers and create three-dimensional objects.
This technique enables manufacturers to replicate complex geometries that are difficult or otherwise impossible to produce using traditional manufacturing methods. It is also widely used for prototyping due to its versatility and relatively low cost. Additionally, FDM 3D printing offers a short turnaround time, allowing for rapid prototyping and iterative design.
Nevertheless, the part tolerance of FDM 3D printing is rather limited as it is prone to minor errors, so it may not be suitable for applications requiring fine details. Plus, the production volume of FDM 3D printing equipment may be lower than other direct prototype tooling methods.
Image Source: Ideogram
Stereolithography
Stereolithography (SLA) is an additive prototype tooling process that utilizes a laser beam to solidify and cure individual layers of a photopolymer resin, creating a three-dimensional object.
SLA can rapidly produce prototype tools with excellent dimensional accuracy and surface finish, even if the design is complex. The prototypes created with SLA can also be easily customized with paint or dye for presentations and trade shows.
The drawback is photopolymer resins for SLA can be relatively expensive. There are also size limitations to the size of prototypes that can be produced using SLA.
Image Source: Ideogram
Selective Laser Sintering
Selective Laser Sintering (SLS) is another additive prototype tooling process that utilizes a laser beam to fuse thin layers of powdered materials to create three-dimensional products.
Compared to SLA, SLS offers greater flexibility for material options, allowing for the creation of prototype tools with properties closer to those of production materials, whether it’s metal, plastic, glass, or ceramic. Moreover, SLS has higher build volumes, so the prototypes it builds can be larger and stronger prototypes than those made with SLA.
Yet, the powdered materials for SLS can be expensive as well. In addition, SLS may produce parts with a rougher surface finish compared to SLA, so it often requires more extensive post-processing steps to remove excess powder and improve the surface finish. This can add to the overall lead time and cost.
Indirect Prototype Tooling Production Techniques
Indirect prototype tooling involves creating an intermediate mold or pattern, which will serve as a master model to produce multiple prototypes. The master model itself may be produced using methods like 3D printing or CNC machining, and it can be fabricated with various materials, including silicone, metals, etc. Once the master model is made, it will be used to create the prototype tools through injection molding or other production processes.
Examples of indirect prototype tooling techniques include:
Silicone Rapid Tooling / Urethane Casting
The process begins by placing the master pattern into a mold box and surrounding it with liquid silicone. After the silicone cures, the master pattern will be removed, leaving behind a flexible silicone mold. Molten polymer (e.g. rubber, silicone, etc,) or urethane resin can then be added into the mold to cast a prototype tool.
Compared to metal, this prototype tooling production method is cost-effective and also has a fast turnaround time due to its simplicity. While the polymers or urethane resin can made into prototype tools with varying hardness and transparency, the material options are still limited by the silicone mold's temperature resistance. What’s more, the silicone molds, being flexible and relatively soft, can deform under pressure. This can make it difficult to extract the complex tools without damaging either the casting or the mold.
Image Source: Freepik
Metal Injection Molding
Prototype tooling production with metal injection molding (MIM) is relatively more complex. It starts with preparing a mixture of powdered metal and binder, which will be injected into the master mold’s cavity under high pressure and temperature. This allows the binder to melt and helps distribute the metal particles evenly within the master mold.
After the molding process, the binder is removed from the part through solvent extraction, thermal debinding, or chemical debinding. The molten metal will then be sintered in a furnace to form a solid, dense metal prototype tool, which can finished with machining or polishin to achieve the desired surface finish and tolerances.
Image Source: Freepik
Metal injection molding can be done with various metals to attain different textures and properties, but manufacturers will usually opt for softer metals when it comes to prototype tools. Here are some of the materials that are commonly used:
Aluminum
Aluminum injection mold tooling offers a balance of speed, cost-effectiveness, and mechanical properties, as the ease of machining allows for rapid turnaround times, making it a valuable option for prototype tooling.
The downside is that prototype tools made with aluminum may possess relatively lower durability or surface finish. Additionally, aluminum prototype tools may not be compatible with corrosive materials or those with reinforced fibers, as they are prone to abrasion.
Soft Steel
Low carbon steel such as P20 will be pre-hardened in its carburized condition with chromium or nickel alloy additives to create prototype tools. This offers the prototype tools greater strength and durability.
In spite of that, steel is still susceptible to corrosion from certain polymers, such as PVC, which can damage the tool's surface. On top of that, being made with harder materials, steel prototype tools generally take more time to machine, resulting in a longer turnaround time overall.
Steel/Aluminum Hybrid
Certain manufacturers may take a hybrid approach in injection mold tooling, by incorporating a steel core and cavity within an aluminum prototype tool. This combines the best of both worlds, offering the speed and cost-effectiveness of aluminum prototype tooling with the durability and strength of steel. Nevertheless, hybrid prototype tooling may still have limitations in terms of surface finish detail and texture compared to traditional steel prototypes.
Comparison: Different Types of Rapid Tooling Techniques
So, how to know which type of rapid tooling method is best for you? It is crucial to carefully consider factors such as material, budget, lead time, level of detail, required strength, production volume and other relevant criterias to select the most suitable prototype tooling technique for your project.
With the following table, we will provide a comprehensive comparison of various rapid tooling methods, including both direct and indirect techniques. The table also includes production tooling (hard tooling) for reference, allowing you to evaluate the trade-offs between rapid tooling and traditional manufacturing methods.
| Methods | Additive Production (like 3D Printing) | CNC Machining | Silicone Tooling / Urethane Casting | Aluminum Injection Tooling | Hybrid Metal Injection Tooling | Soft Steel Injection Tooling | Hard Tooling |
|---|---|---|---|---|---|---|---|
| Tool Material | Filament or resin | Metals, plastic, wood, etc. | Molten polymer or urethane resin | Aluminum alloys | Aluminum and steel hybrid | Soft steel alloys | Actual material for production |
| Turnaround for First Tool | <1 day | 2-3 days | 5 days | 25 days | 32 days | 40 days | 60 days |
| Average Mold Cost | No mold required | No mold required | $1000 | $3000 | $3500 | $4000 | $5000 and above |
| Cost per Tool | Low | Moderate to high, depending on material | Low | Low to moderate | Moderate | Moderate to high | Highest |
| Design Accuracy | Moderate | High | Low | Medium | Medium | Medium | Highest |
| Surface Finish | Limited | Limited | Good | Limited | Good | Very Good | Very Good |
| Withstandable Clamp Pressure | < 100 tons | < 100 tons | < 100 tons | Est. 100 tons | Est. 100 tons | Est. 600 tons | Est. 2,000 tons |
| Tool Lifespan | 1 to 5 shots | 1 to 5 shots | 20 shots | 10,000 shots | 35,000 shots | 50,000 shots | Est. 1 mil. shots |
| Tool Cycle Time During Application | 5-24 hrs | 5-24 hrs | 24hrs | Seconds to minutes | Seconds to minutes | Seconds to minutes | Seconds to minutes |
If you are still not sure which prototype tooling method to choose, you can always consult an experienced manufacturer and let them know about your production process parameters to ensure that the prototype tools are suitable for the intended purpose.
The Benefits of Prototype Tooling
Improved Product Quality
Prototype tooling allows for thorough testing of the tool’s functionality, allowing engineers to evaluate the specifications of the physical object and quickly refine their designs if necessary. This ensures that the tool meets performance expectations during production, leading to improved quality of the final product.
Reduced Time-to-Market
If there are any issues with tooling, design reiteration during mass production would inevitably cause delays. With the faster production times of prototype tooling, engineers can quickly test out design concepts over and over again in the early stages of development. This can significantly streamline the entire production process to improve efficiency and reduce the risk of delays, allowing products to reach the market sooner.
Design Versatility
Prototype tooling can be used with a wide variety of materials, allowing manufacturers to experiment with different options and select the most suitable material for their product. The geometry and other specifications of these prototypes tools are also fully customizable, so manufacturers can easily modify the design to meet the specific needs of their products.
Cost Savings
Prototype tooling is generally less expensive than production tooling. Not only is it a more affordable option for product testing, but it can also help prevent costly reworks or material wastes, as the design flaws can be identified and addressed early on.
Common Applications of Prototype Tooling
Prototype tooling has a wide range of applications. Industries that leverage prototype tooling include:
Automotive: Prototype tools can be used to develop various automotive components, from engine blocks, exterior panels, to other interior parts. This helps manufacturers to assess the product design thoroughly and refine its performance.
Aerospace: Aircraft components such as turbine blades and engine components can be developed at a lower cost with prototype tooling. So, engineers can test the of these components functionality repeatedly, ensuring the safety of the planes.
Consumer Electronics: Prototype tools may be used to evaluate the design of both interior and exterior components for smartphones, laptops, tablets, and other electronic devices. With this, manufacturers can ensure the aesthetics and functionality of consumer electronics.
Machinery: By developing machine components and heavy-duty tools with prototype tooling, manufacturers of industrial and agricultural machinery can evaluate their performance to improve equipment efficiency and minimize defects that pose safety hazards.
Healthcare: With prototype tooling, medical and healthcare devices like prosthetics, implants, surgical instruments, and monitoring equipment can be tested and optimized efficiently at a cost-effective rate during product development. This is important for ensuring their safety and effectiveness.
Interior Design: Prototype tools can be used to create samples of furniture pieces, lighting fixtures, decorations, and other interior products. With this efficient method of creating physical prototypes, designers can verify the visual appearance, comfort, and overall functionality of the final products.
Image Source: Freepik
Reliable Prototype Tooling Services at Teamsworld
With its cost-effectiveness, efficiency, and versatility, prototype tooling can be a valuable resource for product development and innovation. Whether you need prototype tooling for molding or any other manufacturing process, Teamsworld has got you covered!
As a leading manufacturer, Teamsworld is dedicated to delivering quick and reliable services for product development. Our expertise in Design for Manufacturing (DFM) ensures that your prototypes closely resemble the final product. Our capabilities also range from casting to injection molding, thermoforming, and more, allowing us to provide tailored solutions for diverse client needs. l
With a track record of high-quality products and customer satisfaction of over 20 years, Teamsworld has earned ISO 9001:2015 and IATF 16949 certifications, reflecting our commitment to design precision and efficiency. Beyond technical excellence, we also prioritize sustainability as a B-Corp-certified manufacturer, by using a cloud-based project management to streamline production processes and reduce our carbon footprint.
Turn your product vision into reality today! Contact Teamsworld today for a free consultation and let our experts guide you through every step, from design development, prototype tooling, to the final product assembly.