We can either use your existing tooling/molds/fixtures or our team can create them for you.
Upon review of the part with the customer, multiple factors are evaluated to determine the correct tooling to use. Cost being one of the largest factors along with volume, surface finish and geometric features. Aluminum tools cost the most and wood cost the least. A brief description of each type follows. VIP will, through the design for manufacturing (DFM) process, design the tool for your part and supply the data to the tool maker.
If you have us do your tooling we utilize several types of materials. There are generally four different types of materials used to make forming tools – Wood, Synthetic Tooling Board, Composite Lay-Up and Aluminum. Each of these have different versions. VIP has worked with these types of tools and can purchase of them from specialized tool makers or producing them in-house as necessary. VIP’s in-house tool making capabilities lie primarily with wood and synthetic, but we work with qualified and respected 3rd party suppliers for Composite and Aluminum versions. Tooling or fixtures used in the trimming process are designed to hold the parts in place by the use of vacuum while being cut to the final version for shipment.
Aluminum Tooling
Aluminum Tooling is the most durable tooling that is typically used. It can be produced with polished surfaces for parts that are clear or parts that require very smooth surface finishes. Many times, the finish is only sand blasted to reduce overall cost. This material provides the most leeway with regards to design and features. Aluminum tooling is used when higher quantities are required, as you are able to make it with water lines and control the surface temperature and produce consistent parts as well as potentially lowering process times. Because of the process and material used for these tools, it has the highest cost.
Composite Lay-Up Tooling
Composite tooling is less durable than aluminum, but still provides a seamless tool with consistent surface finish. There is no temperature control such as water lines, but the materials used dissipate the heat transferred from the plastic quickly between parts. The tools utilize less costly materials, but require specialized labor and processes to achieve a finished tool. It takes slightly less time to produce a composite tool than it does an aluminum tool. Tools can last a long time, but are more susceptible to damage and subsequent repair than aluminum. Cost of composite is less than aluminum and may be a viable alternative to aluminum for medium to high volume part.
Synthetic Tooling
Synthetic tooling, commonly referred to as tooling board, has a wide range of densities and sizes. The varieties/densities of tooling board available allow VIP to determine the appropriate material for your project. Tooling board is the most versatile option, but has limitations in structural stability and volumes. Tooling board is a cost-effective alternative for short to medium run applications. VIP has the in-house capabilities for the production of synthetic tooling.
Wood Tooling
Wood tooling is most frequently used for rapid prototyping and proof of design. It is possible to use wood tooling for low quantity production. This tool produces the lowest quality of surface finish, but is also least costly alternative. VIP has the in-house capability to produce wood tools to get you project started.