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About injection mould tooling
In 1999, Materialise started an aluminium tooling division in the UK: RapidParts.
The integration of all processes from initial part discussion, over tool design to actual injection moulding, all supported by in-house developed software, contributed to RapidParts' impressive growth. This Materialise activity now supplies both prototype tools and production tools, which has gained them an established reputation in the tooling business. Continuous improvement of our aluminium tooling technologies and software has resulted in a growing demand for small series production parts.
Materialise's unique approach to tooling
The Materialise manufacturing approach guarantees a stable working environment and output. We consistently realise fast throughput times and reliable quality.
Our unique approach to tool design and manufacture allows production of sample components 2-4 weeks faster than the industry’s average. We achieve short lead-times through an optimal integration of all processes from initial part discussion and tool design to actual injection moulding. Data handling and processing and machine control are fully automated, based on Materialise’s 3-matic software package. The entire process is supported by computerised logistics and a trolley-based material flow.
We call our approach the assembly line concept.
The aluminium tools for injection moulding are produced directly from STL files. Our customer’s CAD file is converted into an STL file using Materialise Magics software. This software package is used for tool analysis and quoting. Our 3-matic software is used in the tool design and in preparing the inserts. In the tool design stage a plastic flow analysis is carried out as a final fill check. The core and cavities, saved as STL files, are exported into Magics Mill module, an STL based CAM package, to generate tool cutter paths and optimal control data for the High Speed Milling machines.
Based on the generated bill of material all standard parts, raw materials and prototype models for each tool are brought together on a trolley. This then forms the starting point for the tooling assembly line. The trolley concept improves efficiency and reliability, by keeping all subcomponents together in an organised way, all the way to final assembly.
We rely on concurrent manufacture of cores, cavities, slides, inserts, plate work and electrodes. Once the parts have been machined and inspected they are placed back onto the trolley and moved down the production line. When all machining and spark erosion has been completed, the trolley is moved to the toolmakers for assembly.
Assembly of the tool is efficient and quick. All components are directly available on the trolley. Because of the computerised approach, they fit seamlessly together to form a tool that is ready for the injection run that gives the first moulded sample.