The advantages of Rapid Tooling using the example of the Proceq GP8000

Initial situation and objectives

The Proceq GP8000 for condition testing of concrete structures such as bridges. The device is technically highly complex, is manufactured in small quantities and must meet the highest requirements in terms of precision and reliability.

The challenge: production had to be flexible, adaptable and demand-oriented - without high tool costs or unnecessary warehousing.

Our solution - from prototyping to small series

mould2part produced almost all plastic components of the GP8000, including housing elements and wheels by injection molding with milled aluminium tools.

THE RESULT

• Significantly faster market launch
• Reduction in tool and production costs
• Economical small series production without warehousing

The tooling is stored with us so that our customer can reorder at any time if required.

Technical implementation

The handle of the GP8000 is a particular highlight: it combines hard and soft components and is equipped with three threaded inserts. We developed three injection molding tools to create this complex handle.

Hard component tool

This tool is equipped with a hydraulic slider, two mechanical sliders and a manual insert for threaded bushes. The latter was implemented as a subsequent adaptation at the customer's request in order to be able to directly overmould the originally manually pressed-in inserts - a flexible tool assembly made possible by our manufacturing process.

Soft component tool I

For the soft grip elements, we use a medium-sized mold with three mechanical slides and one pneumatic slide. Here we use a special material for the overmoulding areas to ensure optimum sealing and a high-quality feel.

Soft component tool II

Another, smaller tool is also intended for soft components and has three mechanical slides and a manual insert. Here, too, we use special material to ensure the quality of the gripping elements.

Conclusion - Economical and flexible small series with rapid tooling

Depending on the component, our prototype tools enable quantities of up to 100,000 and therefore form the ideal basis for cost-effective small series such as the GP8000. The Rapid Tooling manufacturing process offers our customers maximum flexibility as well as high time and cost efficiency. Even with three manufactured tools and manual inserts, Rapid Tooling is more economical for him than investing in classic series tools.

Although the production process is not fully automated and three separate injection molds are required, our innovative injection molding process for small series remains more cost-effective than series production. Our technology also offers the flexibility to implement adjustments quickly and easily, which is particularly advantageous for small series.