As reported by The Fabricator in their article “Prototyper Proves to Be Missing Link for Tooling Manufacturer”, Tooling Systems Group (TSG), a Tier 1 supplier of high-volume stamping dies to major automotive OEMs like GM, Ford, and Toyota, identified a critical gap in their operations: the lack of in-house prototyping capabilities. To address this, TSG acquired Auto Metal Craft (AMC), a Michigan-based prototyping company renowned for its expertise in short-run stampings and tooling. The acquisition, completed in August 2022, significantly strengthened TSG’s ability to offer rapid, low-volume production solutions.
Why Prototyping Matters
Despite advances in computer simulations, physical prototypes remain essential for validating part designs, conducting crash tests, and troubleshooting production issues. AMC’s President Chuck Karch emphasized that prototyping allows manufacturers to identify design flaws early and make necessary adjustments before mass production begins.
Prototype vs. Hard Tooling
Prototype tooling differs from hard tooling in several key ways:
- Material: Prototype tools often use Kirksite, an aluminum-zinc alloy that can be remelted and reused, making it cost-effective for low-volume production. Hard tools, in contrast, are made from durable steel like D2 for high-volume runs.
- Process Speed: Prototyping is faster, with simple dies ready in as little as 2-3 weeks and complex assemblies completed in 6-8 weeks. Hard tooling, however, can take up to 30 weeks to design and build.
- Volume Capacity: Kirksite dies can typically produce up to 1,000 parts, while steel dies are used for higher-volume needs and tougher materials.
Efficiency Gains with Prototyping
Prototype tooling enables AMC to produce short runs quickly by combining manual feeding and laser trimming, bypassing the need for intricate in-die operations. This streamlined approach helps customers meet urgent production timelines without the extended lead times associated with hard tooling.
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Article with all rights reserved, courtesy of thefabricator.com.
