The term 'rapid tooling' can mean different things to different people, and choosing the right type of prototype process is often a confusing challenge. "Not all rapid tooling is the same," emphasizes Jason Bassi, director of Quick-Turn Manufacturing Sales. "Its scope has become completely stretched, and it means something different to everyone. I have found that if you ask a group of product development engineers to define prototype or rapid tooling, the definition varies depending on the specific needs or requirements. This often leads them to select an inferior option that delays their new-product launch date and ends up costing them money."

Quick-Turn Manufacturing (QTM) is a new menu of tooling and molding options at Spectrum Plastics Group, a Minneapolis-based plastics company offering a range of product development services including rapid prototyping, rapid tooling and production molding. The DynaClass system includes a new menu of tooling and molding options that further differentiates Spectrum as "quick-turn tooling and molding experts," said the company. DynaClass refers to a new class of rapid tooling and molding capabilities available through the Company's Dynacept Division. It is geared towards simplifying the selection of tooling for a variety of applications, and aligning customers in the medical, aerospace, defense and precision industrial markets, the best molding solution for their application.

QTM's DynaClass hopes to end the confusion by clearly defining the different tooling and molding options that are available. "This helps our customers avoid locking into one solution that may not be optimal for their application," Bassi explains.

Four classes of rapid injection molds

The company outlines four classes of rapid injection molds, starting at the most basic prototype application - DynaClass 1 - up through DynaClass 4, which is similar to class 103 'bridge' tools. "This set of offerings helps our customers select the process best for them to meet their new-product development requirements at exactly the right time in the lifecycle," Bassi says.

In many applications, the company uses M.U.D. (multi-unit die) sets with interchangeable inserts to provide a core and cavity that produces parts in the chosen material that can be used for testing, marketing, or even put into the end-use product. Bassi explains that where QTM fits well is at the point in which the customer's design is 90% complete. "They're far enough along that the design may be frozen, but not 100% sure, so they need some steel safe areas.  They then need parts for design validation, FDA approval and process validation, which we can provide," Bassi adds.  "Our Fast Track program takes that tool, which is typically a DynaClass 3 or 4 tool with an independent frame, validate the tool, the parts, and the manufacturing process showing repeatability with those tools."

The DynaClass 1 and 2 tools tend to have more hand-loaded inserts rather than automation, and more operator assistance.  "At this stage, customers are not really putting a lot of money into the tooling, but they need 1000 parts and want a way to do it cost effectively," says Bassi. "The sweet spot for this is the lower-volume parts."

QTM's goal is to provide production quality parts through its DynaClass program, in a timeframe of 3-4 weeks and with the right type of tooling for their needs. "We're not asking customers to make their part design fit our process," Bassi says. "Some people will always need a true prototype part. What we offer is pre-production parts with the actual material required. It comes down to what the customer needs."

Spectrum Plastics Group has four facilities integrating multiple production manufacturing and rapid prototyping facilities in Colorado, Connecticut, Minnesota and New York to provide a seamless transition to customers for each step of the product development process.