Rapid Tooling Service

Rapid Tooling Service is a practical choice when you need the right balance of performance, finish, and cost for functional parts.

Rapid Tooling — Practical Tooling Without the Upfront Risk

Rapid tooling is about getting functional tools into your hands quickly, without the long lead times or high upfront costs that come with traditional tooling methods. For many businesses, especially small manufacturers, engineers, and restorers, committing thousands of pounds to injection mould tooling simply is not viable at the early stages of a project.

Using advanced 3D printing and CAD-led design, we can create jigs, fixtures, moulds, and functional tooling that are fit for purpose and ready to use in days rather than months. This allows you to test, validate, and refine your tooling before committing to large-scale production methods.

One of the biggest advantages of rapid tooling is flexibility. Designs can be adjusted quickly if something needs to change. If a tolerance is slightly off, or a feature needs strengthening, the tooling can be modified digitally and reprinted without starting from scratch. That level of adaptability simply does not exist with conventional tooling.

Material choice also plays a critical role. Depending on the application, tooling can be produced in ABS, PETG, or other engineering-grade materials to suit strength, wear resistance, and environmental exposure. If a tool is subject to repeated mechanical movement or pressure, we can increase infill and wall thickness to ensure durability.

Rapid tooling is particularly effective for low- to medium-volume production, legacy part replication, and specialist applications where traditional tooling costs cannot be justified. It bridges the gap between prototype and production, allowing businesses to move forward with confidence.

At Mitchell & Son Additive Manufacturing, rapid tooling is not about cutting corners. It is about using the right technology in the right way to solve real problems, reduce financial risk, and keep projects moving forward.

From CAD to Functional Tooling, Fast

Every rapid tooling project starts with understanding how the tool will be used. Is it purely for alignment? Will it experience force, heat, or repeated movement? These questions guide the entire design and manufacturing process.

We begin by creating or refining a CAD model, ensuring the tooling is designed specifically for its intended task. Unlike traditional methods, changes can be made quickly at this stage, allowing us to optimise the design before anything is physically produced.

Once the design is finalised, the tooling is manufactured using high-precision 3D printing. This allows for complex geometries, internal structures, and custom features that are often difficult or expensive to achieve using conventional tooling methods.

Strength is controlled through print orientation, wall thickness, and infill percentage. For tooling that needs to withstand stress or regular use, we increase material density to deliver reliability and longevity. For lighter-duty applications, material usage can be reduced to keep costs down.

Post-processing options are also available. Tooling can be sanded, reinforced, or coated to improve surface finish and durability where required. This is particularly useful for moulds or tools that interact directly with finished components.

Rapid tooling provides a practical, scalable solution for businesses that need results quickly. It allows you to test real-world performance, refine designs, and move forward without committing to expensive tooling too early in the process.

Reducing Cost Without Compromising Function

Traditional tooling often comes with a financial barrier that stops projects before they even begin. Injection mould tooling alone can cost several thousand pounds, before a single part is produced. Rapid tooling removes that barrier.

By using additive manufacturing, we can produce functional tools at a fraction of the cost. This makes rapid tooling ideal for short production runs, replacement tools, and legacy components that are no longer available commercially.

The real value lies in validation. Instead of guessing whether a tool will work, you can physically test it in your process. If improvements are needed, the design can be adjusted quickly, avoiding costly mistakes further down the line.

Rapid tooling is widely used for assembly jigs, drill guides, alignment tools, moulds for casting, and specialist fixtures. These tools are designed to do a specific job efficiently, without unnecessary complexity or expense.

Material selection ensures performance matches the application. PETG offers improved UV resistance and surface finish, while ABS provides strength and rigidity for indoor or controlled environments. Each project is assessed individually to ensure the correct balance of durability and cost.

This approach gives businesses control, speed, and confidence. Rapid tooling is not a temporary workaround; it is a smart manufacturing strategy.

A Smarter Route to Production Readiness

Rapid tooling plays a critical role in bridging the gap between design and full-scale manufacturing. It allows businesses to move forward without waiting months for traditional tooling to be produced.

By creating functional tools early, processes can be tested, refined, and proven. This reduces risk and ensures that when full production tooling is commissioned, it is done with confidence and clarity.

Rapid tooling supports innovation. Design changes can be implemented quickly, encouraging iteration rather than hesitation. This is particularly valuable in product development, restoration projects, and bespoke manufacturing.

The ability to control strength, finish, and material properties means tooling is purpose-built, not over-engineered. You only pay for what you actually need, when you need it.

At Mitchell & Son Additive Manufacturing, rapid tooling is approached as a collaborative process. We work with you to understand the problem, design the solution, and deliver tooling that performs in real-world conditions.

It is a practical, cost-effective way to keep projects moving and ideas becoming reality.

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