Guide to Tool Design: Fundamental, Types & Objectives

Explore manufacturing tool design with us, covering essentials from cutting tools to advanced methods like CAD/CAM. Learn about planning, precision, and various tool types, including computer-aided, rapid, and composite tools.

Discover the objectives of tooling design—cost-saving, quick deliverables, user-friendly designs, and more. We emphasize the importance of tool design in optimizing manufacturing through Design for Manufacturing (DFM) and ensuring worker safety.

Let this guide provide you all the information you need about Tool Designs!

A Brief Definition

Tooling refers to the various accessories and equipment used in manufacturing processes, such as cutting tools, dies, injection molds, work-holding devices, etc.

It is integral to any operation that manufactures products from different components or raw materials.

Tooling design goes beyond form and fit; it provides a solution for specialist needs such as tolerances and precision control, tool life expectancy for production volumes over time, health safety features, etc.

All these factors are essential considerations when designing effective tools that use specific materials within their environment during production operations.

What is Tooling Design in the Manufacturing Industry?

Tooling design in the manufacturing industry uses advanced technology like CAD/CAM systems and heat treatment to create tools for various tasks.

This specialized engineering area involves analyzing production variables while considering practical design, cost management, workforce expertise, and efficiency.

Tooling design aims to help manufacturers reduce product costs by ensuring that tools are properly designed and fit for their intended purpose.

Force control is a key focus, achieved through proper gaging and inspection, ensuring machines function optimally under any production conditions.

Heat treatment is vital, offering benefits like increased hardness, improved dimensional stability, and enhanced fatigue life or elongation properties. This makes it an invaluable tool for creating components with optimal features for manufacturing.

What are the Fundamentals of Tooling Design?

Tool design is guided by fundamental considerations such as planning ahead, selecting the suitable material, precision and accuracy of production, tool change time, as well as durability and volume.

Learn more about how to apply these concepts in your machining operations.

Plan Ahead

Planning ahead involves setting clear goals, choosing materials, and determining precision needs, production volume, and durability.

Good planning saves time and money, ensures timely decisions, meets customer expectations, and enhances user experience.

It also helps coordinate manufacturing tasks efficiently, from CAD drawings to fabrication services.

Selecting the Right Material

Consider factors like structural strength, temperature resistance, and corrosion protection to match materials with technical needs.

Production volume, durability, cost, and ergonomic considerations, including anti-vibration materials for reducing user fatigue, are also vital in selecting materials for tooling projects.

Tolerance and Precision

Having precise measurements and allowing for some variation is important when designing tools.

You need to know exactly how accurate things need to be, the quality of the surface, the strength of the cutting tools, and how precise the shapes need to be.

Even small differences within these set measurements can seriously affect the final product's quality and accuracy.

It's essential that the engineering drawings match up and that different machines used in manufacturing have similar levels of accuracy.

Choosing the right materials for tools is super important, too—it keeps things consistent during production and helps save money.

Tool Changing Time

Tool changing time is vital in manufacturing, involving the movement of tools between operations. Effective planning minimizes downtime, boosts efficiency, and cuts costs.

Factors like material quality, tool size, and tasks affect change frequency, but the aim is swift changeover. Regular maintenance prolongs tool lifespan, reducing labor costs from frequent replacements.

High-quality materials, like hard steel, endure longer, enabling measures such as resharpening and calibration to minimize downtime and costs.

Engineering expertise in design aids in reducing setup times by considering size, tolerances, and precision requirements based on usage scenarios and applied forces.

Production Volume and Durability

The efficiency and durability of tooling design significantly impact production volume in manufacturing.

Prioritizing productivity and durability leads to more sustainable outcomes. Tooling designers must choose durable materials and understand the influence of ideal tolerances on tool performance over time.

Higher initial capital expenditure for reduced tolerance levels results in longer-lasting tools, enhancing efficiency over extended periods, as opposed to loose tolerances that wear out faster, leading to frequent maintenance and loss of precision sooner than anticipated.

Tool Life and Maintenance

The design of a tool, such as cutting or injection molding tools, largely influences its lifespan. Regular maintenance, like sharpening or replacing worn parts, helps extend the longevity of the tool.

Choosing durable materials, like heat-treated steel, in the automotive industry minimizes the need for frequent maintenance and ensures optimal performance over time.

Heat Treatment

Heat treatment is a process designed to manipulate the physical properties of metal, usually tool steel, by heating and cooling.

Heat treating enables the desired characteristics for particular operations in the manufacturing industry.

Different techniques include annealing, case hardening, precipitation strengthening, tempering, and carburizing.

Cost Considerations

Tooling design significantly influences manufacturing costs and the quality of the end product. Accurate estimation is crucial for creating cost-effective tools without compromising quality or precision.

Factors like production volume, durability, heat treatment time, and material choices impact total cost, emphasizing the importance of careful consideration when crafting manufacturing tools.

Health and Safety

Focusing on ergonomic design for hand tools is crucial to reduce user discomfort and prevent injuries. Incorporating health and safety principles from the beginning helps minimize the need for retrofits or additional protective gear.

When using hand tools, it's important to follow general safety procedures, including maintaining a comfortable work posture, using proper grips, and avoiding forceful activities that can cause stress on the body.

Portable power tools should always have guards to protect users from debris and other hazards.

Some factories use diagnostic wearables or sensors in employees' uniforms to monitor temperature changes during manual labor, helping measure fatigue levels. This allows for timely preventive measures if needed.

A healthy workforce enhances productivity, reduces waste, and saves costs over time. Investing in health and safety is not only imperative but also economically sensible.

Typical Types of Tools

There are multiple types of tooling for various applications, from cutting tools, dies, and injection molds to work-holding tools.

Explore these options and make the best decision for your needs.

Cutting tools

Cutting tools shape raw materials into various products. They vary in types, like lathe tools for metal and woodworking tools like saws, chisels, and planes for wood.

Their geometry defines their functions - drills for holes, facing cutters for flat surfaces, milling cutters for contours, and more.

Material choice matters too; diamond/CBN for hard metals, carbide for non-metallic substances, and high-speed steel (HSS) for cost efficiency.

Dies

Dies are specialized tools crucial for mass production, differing from general tools in their fabrication processes.

While often used interchangeably, "tool" involves direct machining, while "die" necessitates precision finishing.

Their diverse types cater to different functions: Stamping dies produce items from small jewelry to large car panels, while sheet metal dies shape intricate parts from thin materials.

Progressive dies handle multiple steps in one tool, blanking dies cut without excess material, and piercing dies create consistent slots or holes.

Injection Mold Tools

Injection mold tools are used for making plastic parts. They're made of durable steel for efficiency, incorporating guide pins to reduce wear.

Choosing the right steel grade is crucial for balancing strength and hardness.

While CNC machining ensures precision for automotive prototyping, using softer materials is better for high-volume production to avoid brittleness and potential damage, necessitating wear-resistant materials.

Work-Holding Tools

Work-holding tools secure, position, and support workpieces during operations, enhancing cutting accuracy and efficiency.

They come in various forms, like jigs, clamps, fixtures, tool holders, and specialized systems.

Choosing the right tool depends on its specific function, such as positioning workpieces, supporting cutting tools, connecting machines, facilitating multitasking, or enabling quick piece exchange.

Fixture Tools

Fixture tools aids in securely positioning and supporting workpieces during cutting processes.

They ensure precision, reducing rework, saving time, and avoiding errors. Jigs guide cutters, while fixtures precisely position tools or materials.

Fixtures typically aid workpieces moving past cutting tools, optimizing setup times and boosting production rates through accurate machining.

Gaging & Inspection Tools

Gaging and inspection tools are used for precise measurement of metalworking parts, ensuring high-quality products.

Instruments like gages, feeler gauges, and pneumatic gauges ensure dimensional accuracy.

Advanced tools such as Vernier Calipers and micrometers cater to shipbuilding's need for exceptional precision.

Machine tool calibration prevents downtime due to equipment failure, while routine inspections detect defects early, maintaining consistent production quality.

Computer-Aided Tools

Computer-Aided Tools like CAD and CAE software empower engineers by enabling design creation, modification, analysis, and optimization for diverse manufacturing processes.

CAD produces 2D/3D designs usable in production or for patents. CAE offers added features like engineering analysis, design optimization, modeling, prototyping, and supports CNC machining for high-precision manufacturing across industries.

Rapid Tools

Rapid tools are specialized for swift part production, ideal for prototypes or actual products.

They're faster than traditional methods, benefitting the manufacturing industry by ensuring quality while meeting quick deadlines.

There are two types: direct (produces usable parts via 3D printing or CNC machining) and indirect (need finishing processes like heat treatment).

They offer a quick adaptation of existing designs and facilitate efficient iteration on product models through user-friendly computer programs.

Composite Tools

Composite tools, crafted from materials like carbon fiber reinforced polymer (CFRP) or glass fiber-reinforced plastic (GFRP), offer strength and lightness compared to traditional metal tools.

They're preferred for their cost-effectiveness, ease of use, and rapid production.

Fused Deposition Modeling (FDM) composite tooling, specifically, enables swift production with high tensile strength, enhancing precision for complex part manufacturing.

Objectives of Tooling Design

Read further to know more about tooling design by discovering its objectives!

Cost-saving

Tooling design greatly impacts product cost. Cost-saving measures in this area significantly affect a manufacturing company's bottom line.

Ways to cut tool design costs include smart material procurement, resource integration, and efficient planning.

Managing expenses involves analyzing resources, coordinating activities, minimizing waste, and controlling budgets to ensure short-term and long-term financial gains.

Quick deliverables

Timely delivery is essential in manufacturing. It means getting things done on time, meeting quality standards, and controlling costs.

In a digital world, quick delivery times give an edge by reducing customer wait times, boosting efficiency, and using tools like project management systems to set clear timelines and address potential issues early.

Tools like Zeplin help UI designers and developers communicate better, ensuring smoother project progress.

User-friendly

Making tools easy to use is important for successful manufacturing solutions, especially for engineers designing tools.

Simple designs with clear, standout colors help users find what they need quickly. Easy navigation on websites or software makes a brand or product more appealing.

Slow loading and unclear instructions drive users away. Testing tools during production using simulations like Usabilla and Design scenarios ensures they're user-friendly and flexible.

Drag-and-drop features simplify complex tasks for creators. Quick access panels help users get quick results and navigate easily, saving time in the digital space.

Coordination

Coordination is vital in tooling design, ensuring projects finish on time with teamwork. It means organizing resources and activities for everyone's benefit.

Good team communication helps meet goals, manage tasks smoothly, and create sensible schedules. Planning ahead clarifies roles and expectations, preventing mistakes due to misunderstandings.

BIM (Building Information Model) Coordinators, for instance, manage information for projects like 3D printing or machining, ensuring smooth development towards the final goal.

Well-coordinated teams improve efficiency and result in better products and services, saving time, effort, and costs in construction processes.

Improve productivity

To enhance tool design and productivity, grasp fundamental principles like planning, material selection, and considering factors such as production volume and durability.

CAD platforms revolutionize the design process by boosting designer efficiency and streamlining operations.

The Design Productivity Blueprint plays a vital role in elevating manufacturing efficiency by directing resources toward high-value tasks, resulting in improved productivity and output.

Keep Quality

The efficiency and quality of manufacturing depend heavily on well-designed tools that precisely match product specifications.

Design flaws in these tools can hike up costs, delay production, and lower part quality.

Plan tool selection in advance, consider material types, tolerances, heat treatment, rapid creation processes, tool life, productivity, and safety to maintain consistent quality throughout production.

Tool Design General Process

Successful projects rely on problem-solving, meticulous attention to detail across the production cycle. Consider materials, tolerances, geometry, power requirements for machining, surface finish parameters, etc.

Designing tools involves several key steps:

• Understanding the problem or need the tool should address.
• Generating ideas and concepts for the tool's functionality, appearance, and usability.
• Creating detailed sketches, diagrams, or digital models using CAD (Computer-Aided Design) software.
• Building a physical prototype or a digital representation to test the tool's functionality and make improvements.
• Evaluating the prototype's performance, gathering feedback, and refining the design based on test results.
• Finalizing the design, selecting materials, and preparing for mass production if applicable.
• Producing the tool using appropriate techniques (e.g., machining, casting, injection molding).
• Ensuring each tool meets quality standards through inspection and testing.
• Packaging, distributing, and making the tool available for its intended users.

Additionally, following simple rules during prototyping achieves excellent metal-on-metal (MOT) performance with low power consumption.

This consistency fulfills commitments to market competitiveness while delivering top-notch remote services from a single location, offering an outstanding experience at significantly reduced costs over time.

Why is Tooling Design Important in the Manufacturing Process?

Tooling design is important in manufacturing as it optimizes processes through Design for Manufacturing (DFM), ensuring efficient engineering, assembly, cost considerations, and quality maintenance.

It prevents issues like vibration impact, ensures worker safety, and minimizes delays due to material changes by focusing on accurate dimensions and material selection upfront.

Ultimately, it enables manufacturers to succeed by streamlining operations and controlling costs.

Contact DEK for the best tooling design services. We have the best skilled professionals that won’t let you down!

Conclusion

In summary, this guide emphasizes the important role of well-designed tools in optimizing manufacturing processes. It covers key considerations like planning, material selection, precision, and maintenance to create cost-effective tools that enhance efficiency.

This guide discusses various types of tools and outlines the objectives of tooling design, such as cost-saving and user-friendliness. It also explains the general process of designing tools and stresses the importance of tooling design in manufacturing success.