What is Rapid Tooling?

Rapid tooling describes the rapid production of Tools or tool inserts using accelerated manufacturing processes. The term rapid tooling, together with rapid prototyping, has become widespread, particularly due to the spread of 3D printing, but is not limited to additive manufacturing processes. Rapid tooling is primarily used in the Prototype construction, The moulds are used for small series and pre-series production to produce elastic or thermoplastic parts under near-series conditions.

 

Aim and mode of operation

The aim of rapid tooling is to produce functional tools in a short time without any relevant loss of functionality. This often involves accepting compromises in terms of tool life or dimensional tolerance. Typical methods for rapid tooling are

  • Additive manufacturing of basic mould bodies (e.g. made of plastic, Aluminium or resin)
  • Milling of so-called soft tools made of less hard materials (e.g. aluminium or POM)
  • Hybrid design with 3D-printed inserts and conventional mould frames
  • Silicone moulds for simpler cast parts

 

In contrast to the classic Toolmaking simplified cooling channels, lower tolerance requirements or softer materials are often accepted. In contrast to the Series production a few days to weeks.

 

Advantages of rapid tooling

  • Short development times with high flexibility
  • Often more cost-effective than series moulds
  • Ideal for functional samples, tests and small series
  • Processes can be tested under realistic conditions
  • Seamless integration into CAD/CAM workflows

 

Typical applications

Typical fields of application are the production of Prototypes in near-series quality, pilot series for testing components before the start of series production as well as the production of small and medium quantities. In product development, rapid tooling enables realistic functional and assembly tests, as the components can be manufactured in the final materials and using the planned production processes. Also for the optimisation of Cycle time Rapid tooling is an important instrument for testing the production concept in early development phases.