Prototype Tooling

Our prototype tooling process starts with CAD-based 3D modeling and simulation of the injection molding process, followed by a Design for Manufacturability (DFM) review to ensure mold efficiency. We typically use aluminum for the tool due to its speed and cost benefits, though steel is an option when needed. Part materials are selected based on performance needs, and the mold is designed to match—ensuring functionality, durability, and efficient production from the start.

Once the design is finalized, the tooling process moves into precision machining. The mold cavities are milled into steel with exacting tolerances, followed by the assembly of all key components—ejector pins, inserts, and cooling channels—to create a fully functional, ready-to-run tool. This stage turns your digital design into a reliable production asset, optimized for accurate testing and validation.

Once the tool is assembled, we begin with initial mold trials—known as T0—to assess dimensional accuracy, part fit, function, and surface finish directly from the mold. Next, during the T1 phase, we produce the first set of parts for full evaluation. This is where First Article Inspection (FAI) comes into play: we verify that critical dimensions meet specifications and assess overall part performance. If issues arise, we fine-tune injection parameters or update the design as needed, allowing for rapid iteration and refinement before moving to full production.

The final phase involves iterative sampling—T2, T3, and beyond—until the customer approves the parts. Each round is an opportunity to refine performance, whether through mold modifications, material changes, or process adjustments. This stage is especially valuable for new product programs, where critical insights emerge. Once the prototype parts meet specifications, the same tool can be used for low-volume production. With durability for up to 10,000–20,000 shots, a well-executed prototype tool may serve as the only tool needed for a project’s lifecycle.