Rapid Tooling

Rapid tooling refers to the fast and cost-efficient production of tools and molds using additive manufacturing technologies. In contrast to traditional methods such as machining or casting, rapid tooling enables flexible production in which designs can be implemented immediately. The technology uses additive processes to precisely realize complex geometries and functional integrations.

The rapid tooling process

In today’s industry, which is characterized by constant pressure to innovate and shorter product cycles, rapid tool production is particularly important. Companies that want to make their manufacturing processes more efficient and react flexibly to changing customer requirements benefit considerably from this method. Rapid tooling with additive manufacturing methods in particular is proving to be a decisive competitive advantage.

Traditional processes often require the complex production of tools and long throughput times. Additive manufacturing, on the other hand, scores points for speed, lower material losses and the ability to implement even the most complex designs. With rapid tooling, near-contour cooling channels or sophisticated cavities are integrated directly into the workpiece to be printed – without any additional processing step.

The advantages of rapid tooling

Faster tool and mold making

With rapid tooling 3D printing, tool components and inserts, for example for injection molding machines, can be created much more easily and quickly than with conventional manufacturing methods. This allows companies to react more quickly to changing customer requirements and adapt products at short notice if necessary.

Cost savings

Rapid tooling with near-contour temperature control is usually more cost-efficient than conventional toolmaking in terms of unit costs. The improved cooling performance of the tool reduces both cycle times and reject rates.

Flexibility

Rapid tooling makes manufacturing processes more flexible, as changes to molds and tools can be made quickly and easily. A new design is simply loaded into the 3D printer and the new tool is printed within a few hours.

Design freedom

Thanks to the three-dimensional layering process, tools with complex geometric structures and cavities can be realized easily and without additional effort. It is also possible to integrate optimized and near-contour cooling channels regardless of the geometry. This significantly improves the cooling performance of the tool during operation. This is also positively reflected in the reduction of cycle times.

Lower risk

Rapid tooling can reduce investment risks as companies do not have to commission expensive tools and molds before they know whether their products will be successful. Instead, they can create tool prototypes quickly and cost-effectively to test and optimize the manufacturing process.

The Rapid Tooling process sequence

1. Construction phase: Development of the tool design including simulations
2. Additive manufacturing: 3D printing of tools exactly according to specifications
3. Quality control: Comprehensive testing of printed objects to ensure functionality and dimensional accuracy

In this process, FKM combines modern machines and innovative methods with a high level of expertise to achieve optimum results.

Our consulting and realization approach

When it comes to rapid tooling, FKM also sees itself as a project partner that supports customers beyond pure additive manufacturing: We already think along with the design process of a product.

When it comes to rapid tooling, we keep an eye on all the possibilities of 3D printing – from resource-saving lightweight construction to functional integration such as conformal cooling channels, specification-dependent material recommendations, alternatives for finishing and the final assembly of components. FKM is open to your ideas and is passionately committed to their realization with LBPF solutions. This reduces the development risk and secures further investment steps.

Rapid Tooling at FKM

FKM sees itself as an innovative project partner in the field of rapid tooling. FKM contributes its expertise as early as the product design process in order to develop optimum solutions. State-of-the-art laser sintering technologies in the powder bed process and comprehensive materials consulting ensure the highest quality and efficiency.

FKM is passionately committed to the implementation of customer-specific ideas and thus reduces the development risk while at the same time safeguarding investment steps. Get customized solutions that are not only innovative, but also economical.

Areas of application for rapid tooling

Rapid tool production via 3D printing is used in many industries. In the automotive industry, it is used for the fast and cost-efficient production of prototypes and small batches, which enables flexible adaptation of new designs. In medical technology, for example, it is used in the production of high-precision tools for complex devices and implants, whereby additive manufacturing implements particularly delicate structures. In the consumer goods industry, too, rapid tooling enables a quick response to new trends by allowing designs to be adapted at short notice.

Temperature control close to the contour: how we optimize your production

Together with our partner iQtemp, a specialist in near-contour temperature control for rapid tooling, we have perfected the cooling process in additively manufactured tools and molds.

“It’s amazing how cold the component falls out of the tool.”

One example is the collaboration between FKM and iQtemp, in which innovative solutions for near-contour temperature control were developed. This technology shortens cycle times and significantly improves the efficiency of injection molding and die casting tools.

Advantages of conformal cooling from FKM & iQtemp

• Uniform flow of the cooling water
• Very fast, homogeneous cooling of the component
• Cost-efficient integration in the 3D printing process

Materials in rapid tooling

FKM offers a choice of six different metals, which are used depending on the requirements. These include materials with high temperature resistance, tensile strength and break resistance. Specific requirements can be optimally fulfilled through the targeted selection of materials.