Prototyping & Prototype Tooling

The choice of tooling is primarily determined by dimensional specifications and the draw ratio, which are tailored individually for each project based on its specific requirements.

In general, functional criteria take precedence in the decision-making process. If these are not a limiting factor, then considerations shift towards cost-effectiveness in tool manufacturing and production-related variables such as cycle times.

• Positive Molds (Male Molds): With positive molds, the material is formed over a raised contour rather than being drawn into a cavity. Generally, positive molds are more cost-effective to manufacture, but they come with the drawback of more challenging demolding, particularly when dealing with undercuts, complex geometries, or materials with significant shrinkage.

• Negative Molds (Female Molds): In negative molds, the cavity itself serves as the forming surface. The shaping process is achieved through vacuum, compressed air, or a combination of both, ensuring precise form definition. Negative molds are often preferred for detailed surface textures and higher precision applications.

• Single Use: A single-use tool is used when the size of the formed product and the maximum forming area of the machine allow only one part per cycle. It is also the preferred choice for small production runs, where investing in a more expensive multi-use tool would not be cost-effective.
• Multiple Use: If neither part size nor production volume is a limiting factor, a multi-use tool can be utilized. While more complex in design, multi-use tools enable the production of multiple parts per cycle, reducing overall costs and improving efficiency.

An upper punch significantly enhances stretching ratios in negative molds, allowing for ratios of up to 1:7 instead of the typical 1:1.

Since the upper punch acts as a positive tool, pressing the material into the negative cavity, it closely resembles the closed mold setup used in injection molding. This technique improves material distribution and enables the forming of deeper, more complex geometries.

A form-punch tool is a specialized tooling system that combines forming and punching into a single process step, eliminating the need for separate forming and trimming operations.

In thermoforming, form-punch tools are designed for high precision and repeatability, ensuring consistently accurate parts. They are widely used in mass production, where efficiency and uniformity are critical for cost-effective manufacturing.

The design of the forming area is automatically calculated and determined by formary after evaluating your relevant inquiry criteria. The requirements for the deep-drawn part converted into production-relevant processes are decisive.