Tips to Reduce Costs

The designer of plastics tooling must be a capable tool designer who

understands the processes, the machines, the materials being worked,
and the environmental conditions likely to be encountered. The construc-
tion of plastics tools frequently involves standard tool-making methods,
with only some of the working surfaces being made of plastics. In fact,
a plastics tool may often look just like any conventional tool, since only
the materials of construction have changed, not the function of the tool
nor the machine in which the tool is to be used.
Broad design generalizations are difficult to make. A full understanding
of the capabilities of plastics materials is a prerequisite to effective de-
sign. However, there are a number of specific recommendations which
can be made to help realize the fullest potential of plastics as a tooling
material.

Probably one of the most common reasons for using plastics in tools is to
reduce the cost of the tool. The following recommendations can frequently help
reduce costs to a minimum:
1. Simplify tool design. A tool design consisting of word descriptions and
sketches in conjunction with the part print eliminates the need for a complicated,
completely dimensioned drawing, and may be the first step toward cost
reduction.
For example, drill jigs made of glass-reinforced plastics laminates and used to
drill holes in shaped sheet metal parts are frequently made from a sample part
which has the holes drilled in their correct location. Directions for such a tool
might consist of a free-hand sketch, or markings
on the part itself with a written description specifying laminate thickness and the
size and type of drill bushings required.

2. Use existing models or parts. Since plastics is essentially a duplicat-

ing material, a shape must always be present, except in special cases such
as loft template constructions. Whenever possible, use a shape already
available, such as a model or a prototype part, and reproduce this shape
in plastics.
3. Build new models to male shape. When master models have to be
made, build them in a manner easiest to duplicate (usually a male shape),
and to the side-of-metal that requires the least amount of transference
of part thickness.

4. Use flat run-outs. Flat run-outs are easiest to build, and should be
used wherever possible.

5. Eliminate undercuts and loose pieces. Remember that in reproduc-

ing a shape in plastics, the plastics shape must be removed from the
model.
Wherever possible, eliminate all undercuts and loose pieces, simplifying
shape reproduction.

6. Use lattice-type laminates. Lattice-type laminate structures should

be used wherever possible instead of solid structures. Lattice structures
require less material and less labor, and are lighter in weight.

7. Select supporting structures carefully. Each type of supporting

structure has benefits for specific types of tools. Wood is fast and lowest
in cost, but has relatively poor dimensional stability, and well-defined
planes of weakness. Cast iron is next to wood in cost and is readily avail-
able in terms of delivery time, but it may require time-consuming, costly
machining.
Cast aluminum is more costly than iron but usually can be
obtained more rapidly, and is more rapidly machinable. Cast steel is most
expensive and takes longer to get, but offers maximum strength. Weld-
ments are nearly as expensive and as strong as cast steel, and can be
obtained sooner. Fabricated plastics supporting structures can be costly,
both in terms of materials and labor, but offer low weight.

8. Use fillers in plastics tooling materials. Where relatively large masses

of plastics are required and strengths are not critical, fillers can increase
the yield of the relatively expensive plastics materials.

9. Pot large flat tool areas. Slow expensive machining of large areas can
be eliminated by potting surfaces from a surface plate to pads, ribs, or
whole continuous surfaces.

Topwox plastic mold