Rapid Tooling Services | Custom Molds & Prototype Solutions

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At ZUERST, we combine our expertise, engineering capabilities, and advanced technology to deliver high-quality rapid tooling solutions for prototypes and short production runs. Our team collaborates closely with each customer to develop tailored solutions that meet specific requirements. With extensive experience in both rapid tooling and mass production mold making, we are equipped to handle projects of all sizes. If you're ready to scale up to mass production, explore our injection molding services for seamless manufacturing.

Rapid Tooling Processes

Rapid Mold Making

We use machined aluminum or soft steel for mold cavities, allowing for rapid production of low-volume molds. By simplifying mold design and using standard components, we accelerate the process even further.

Rapid Injection Molding

Our facility includes over 10 injection molding machines, ready to handle prototype or small-batch production immediately. Molds are loaded into machines without delay, ensuring quick turnaround times for your projects.

Why Choose us for Rapid Tooling?

The Top 4 Reasons:

Top Quality: We produce high-quality prototype molds that closely match mass production standards, ensuring reliable results for functional testing and short production runs.

Cost Savings: Our experienced engineers design cost-effective solutions by optimizing tooling designs and selecting the best materials without sacrificing quality.

Fast Turnaround: With in-house facilities, a large stock of mold components, and a strong manufacturing network, we deliver rapid tooling and moldings in just days, meeting tight deadlines.

Flexibility: We cater to low-volume and mass production needs without minimum order quantities, providing seamless support as your project scales.

What is Rapid Tooling

Rapid tooling, also known as prototype tooling or bridge tooling, is a fast and cost-effective approach to creating low-volume injection molds for plastic parts. The process uses aluminum or soft steel molds, which are then employed in injection molding to produce multiple copies of a part. This makes rapid tooling ideal for rapid prototyping or acting as a bridge before moving to high-volume production.

The process typically involves aluminum or soft steel molds, along with stock mold bases and hand-load inserts, to speed up manufacturing. It is particularly effective for fulfilling small batch orders, such as marketing samples, product evaluations, or process design testing.

While traditional tooling can be costly for small projects, rapid tooling provides a cost-efficient alternative when large production volumes are not needed. It is commonly used in industrial settings for prototyping solutions, diagnosing design issues, and offering a more accessible introduction to mold making.

At ZUERST, we create rapid molds primarily through CNC machining and EDM, and we sometimes incorporate additive methods, such as 3D printing technologies.

Rapid Tooling Materials

Aluminum Mold Tooling

Aluminum mold tooling is a cost-effective option for prototyping and low-volume production. Its ease of machining reduces tooling costs by 15–25% compared to other materials and can decrease cycle times by up to 40%, resulting in faster turnarounds. The material's ability to dissipate heat evenly ensures dimensional stability, minimizing deformation and waste during production. However, aluminum is less durable than steel, making it less suitable for high-volume production due to its shorter lifespan.

Steel Mold Tooling

Steel mold tooling is a durable and high-quality choice for high-volume production. It offers a longer life cycle than aluminum and is ideal for producing molds that use engineering-grade plastics resistant to abrasion and corrosion. While steel molds provide superior strength and versatility, they are more expensive and require longer lead times for production, making them less suitable for rapid prototyping.

Prototype Injection Molding Materials

Thermoplastics

ABS
ABS/PC
Acetal
Acetal Copolymer
Acetal Homopolymer/Delrin
ETPU
HDPE
LCP
LDPE
LLDPE
Nylon
PEEK
PEI

Standard silicone (30, 40, 50, 60, and 70 durometers)
Medical-grade silicone
Optical-grade silicone
Fluorosilicone (fuel and oil resistant)

PET
PETG
PMMA (Acrylic, Plexiglas)
Polycarbonate
Polypropylene
PPA
PPE/PS
PS
PSU
TPU
РВТ
РС/РВТ

Why should I use rapid tooling?

Rapid tooling is a fast and cost-efficient way to create a few prototypes in a selected material for function and aspect testing, as well as for low-volume manufacturing to test out the market.

How fast can I get the moldings?

This depends on the size and geometry of the parts. For a common open and shut mold with regular size part such as 300 x 300 x 50 mm, fabrication of tools and moldings can be done within 10 days.

What materials can I choose from with rapid tooling?

There is no limit to material choice. Any plastics available for mass production, including common silicone and rubber materials, can also be used with the rapid tooling process.

What is the quality level of rapid tooling?

Moldings from rapid tooling are end-use-parts quality. They are very close to mass production parts.

How many moldings can I get from rapid tooling?

Normally, aluminum molds are good enough for +/- 1,000 shots, while Steel P20 molds can last for +/- 10,000 shots.

Why Choose ZUERST?

Experience and Expertise With over a decade of experience in CNC turning, ZUERST brings unparalleled expertise to every project. Our skilled team utilizes advanced technology to deliver precise and high-quality components, ensuring your project's success. Quality and Certifications We are committed to maintaining the highest quality standards. ZUERST is ISO 9001:2015 and AS9100D certified, guaranteeing reliable and consistent production outcomes that meet industry requirements.

Customer Support Our dedicated customer support team is available 24/7 to assist you. Whether you need technical guidance or have specific project inquiries, our experts are here to provide timely and effective solutions, ensuring a smooth and efficient process from start to finish.

Get Started

Ready to begin your CNC turning project with ZUERST? Request a quote or contact us for more information. Simply upload your CAD files to receive instant feedback and pricing. Our team is here to support you every step of the way, ensuring precision and efficiency for all your CNC turning needs.

Get In Touch With Us

Just leave your email or phone number in the contact form so we can send you a free quote for our wide range of designs!

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