Aluminum rapid tools. Steel production molds. Mold components.

Aluminum rapid tool: $3,000-12,000, 14-day lead time, 5,000-20,000 shot life. Steel production tool: $15,000-80,000, 6-8 week lead time, 500,000+ shot life. Break-even analysis: if production volume uncertain, or market validation needed, start with aluminum. If volume committed at 50,000+ parts, go directly to steel. Many customers use aluminum tool for pilot production, then invest in steel tool once market demand confirmed.

SPI-A1 (mirror, ≤Ra 0.01 µm) for optical parts. SPI-A2 (high polish, Ra 0.05 µm) for premium cosmetic. SPI-A3 (medium polish, Ra 0.1 µm) for general cosmetic. SPI-B (fine stone, Ra 0.4 µm) for draft angles, non-visible surfaces. SPI-C (paper polish, Ra 0.8 µm) for standard production, textured surfaces. SPI-D (bead blasted, Ra 1.6+ µm) for matte appearance. Higher polish = higher mold cost. Specify only what part appearance requires.

P20 pre-hardened: 4-6 weeks typical. H13 with heat treatment: 6-8 weeks. S136 stainless: 6-10 weeks. Complex multi-cavity production tools: 8-12 weeks. Rush service available for 40% premium — cuts 30-40% of lead time. For very urgent programs, hybrid approach: aluminum rapid tool for first production + steel tool in parallel for production ramp.

5-axis CNC is increasingly standard for mold work. Advantages: complex 3D surfaces in single setup, conformal cooling channels, tool access to difficult features, better surface finish on contoured surfaces, reduced EDM requirement. For complex production molds, 5-axis often reduces overall project time and cost despite higher hourly rate. We handle 5-axis mold machining as standard capability.

EDM (sinker): good for sharp internal corners, deep narrow features, hardened material after heat treat. Slow, consumable electrodes required. 5-axis milling: faster, better surface finish, minimum inside radius limited by tool geometry. Modern mold workflow: 5-axis mill as much as possible, EDM only for features impossible to mill. Reduces electrode costs and shortens lead time vs traditional EDM-heavy workflow.

DME mold bases (US standard): stocked sizes from 4x4 to 30x30 inches. HASCO mold bases (European standard): metric sizes. Progressive Components and Futaba components available. We buy mold base sets, machine cavity and core plates to customer specifications, assemble with customer-specified hot runner system or cold runner design. For critical production, full-function testing before delivery.