Low-volume moulding uses machined aluminium or soft-steel tools to produce real injection-moulded parts without paying for hardened production tooling. It is the standard way to validate a market, run a clinical trial batch or satisfy a customer launch date while the long-life tool is still being cut.
Aluminium tools cut in 7–10 days from frozen CAD
Bridge tooling with steel inserts for 5,000–50,000 parts
Pilot runs from 100 to 5,000 pieces per tool
Same gating and cooling design carried into production tooling
Design changes handled with insert replacement, not a new tool
T1, T2 and pre-production sample stages documented
| ABS, PC/ABS, PP and PE |
| PA6 and PA66 including glass-filled |
| POM, PMMA and PC |
| TPE and TPU overmoulding |
| Flame-retardant grades |
| Colour-matched masterbatch |
| Specification | Details |
|---|---|
| Tool lead time | 7–10 days aluminium, 15–20 days bridge |
| Tool life | 3,000–10,000 shots aluminium |
| Quantity | 100–5,000 pcs (per tool) |
| Cavities | 1–8 for pilot tools |
| Tolerance | ±0.1 mm, T1 dimension report supplied |
| Upgrade path | Validated process transfers to production steel |
SPI A2–B2 pilot finishes
Light texture for representative feel
Prototype paint or laser marking
Trim and assembly fixtures
Aluminium tools typically run 3,000 to 10,000 shots. With glass-filled resin or abrasive colours the practical life is nearer the lower figure, so we advise per resin in the DFM report.
The tooling itself rarely does, but the process does. Runner layout, gate position, cooling and pack profile are all transferred, so the production tool starts from a proven recipe.
Dimensional and cosmetic quality can match production because the tool is cut from the same CAD. The difference is tool life and cycle time, not the part.
Rapid aluminum & production steel tooling, T1 samples in 7–15 days.
Production plastic injection moulding from 100 to 100,000+ parts. Hardened steel multi-cavity tooling, 100+ resins, scientific moulding and full PPAP support.
Mould design and manufacture in-house: 2-plate, 3-plate, hot runner and stack moulds in P20, H13 and S136 steel. DFM and mould flow analysis on every tool.
Insert moulding of brass, stainless and threaded inserts, bushings, magnets and metal frames. Load-rated threads and metal-plastic joints without assembly.
Overmoulding and two-shot moulding of soft-grip TPE/TPU over rigid substrates, plus sealing rings and multi-material parts in one production flow.
Send your files today — DFM-checked quotation within 24 hours.