The right toolmaking or mold making for the defense industry

The arms and defense industry faces the constant challenge of developing high-quality products while keeping costs under control.

Given the often small quantities that are typically required, it is crucial to find flexible and cost-efficient solutions in the field of tool and mold making. Striving for competitive prices and high quality results is therefore essential to meet the growing demands of this industry.

In this context, various technologies in tool and mold making are advantageous options. Below we explain some of the most common technologies that can be used specifically for the production of small series in the defense industry.

Injection molding tool for small series

Injection molding is a proven technology for manufacturing precise components in large quantities. However, injection molding is also extremely effective for the production of small series, provided the right technology is used in toolmaking and the partner has extensive experience in the production of prototypes and small series.

Series manufacturers of injection molded parts often show little interest in adapting their machines for small batch sizes, which can lead to considerable set-up costs, especially if subsequent orders also only require limited quantities of plastic injection molded parts. It is therefore advisable to rely on a specialized injection molder who can respond flexibly and cost-effectively to your individual needs.

Injection molding tool — *Injection molding small series with a call-off quantity of 80 units per year*

Mold making from GRP (glass fiber reinforced plastic)

GRP is a lightweight yet robust material that is ideal for mold making. This type of mould construction makes it possible to efficiently realize highly complex geometries. The combination of GRP’s dimensional stability and lightness offers outstanding advantages over traditional materials.

Toolmaking from polymer concrete

Polymer concrete is a composite material consisting of a combination of mineral fillers and a polymer binder. It has become increasingly important in recent years, particularly in toolmaking and in the production of RIM (Reaction Injection Molding) for polyurethane (PUR) products. The combination of high strength, chemical resistance and thermal stability makes it a first-class choice for the production of small batches of up to 1000 pieces

PUR foaming tools

Foaming tools are crucial for the production of PUR (polyurethane) molded parts, and the choice of material for tool manufacture has a significant influence on the service life and quality of the parts produced. Foaming tools made of Ureol or block materials are preferably used for prototypes and initial samples. Aluminum foaming tools are ideal for medium quantities up to approx. 10,000 pieces

Aluminum toolmaking — *Aluminum mould for PU scuff plates*

Silicone tools (silicone mold)

Silicone molds are an important component in prototype development and the production of small series. They enable the cost-efficient production of components made of various materials, including rubber, hard plastics and highly transparent materials such as the plastics used for headlights. The service life of molds made from silicone is between 15 and a maximum of 20 units.

hintsteiner-china — *Demolding a PU part from a silicone mold*

Carbon (CFRP) or CFRP mold construction

Carbon fiber reinforced plastic (CFRP), also known as carbon fiber reinforced polymer, is characterized by a number of outstanding properties. These include its remarkably low weight, even with large shapes, as well as its extremely low thermal expansion, which makes it ideal for applications with changing temperatures.

The service life of carbon molds depends heavily on the specific application and the conditions under which it is used. In general, CFRP is extremely durable and corrosion-resistant. Temperatures up to +250° are possible without any problems

*Laminating a CFRP mold using the wet laminate process*

Master model for CFRP production from aluminum

An aluminum master model is a precise template for the production of moulds for the production of composite materials, especially in autoclave production. The accuracy of these molds is crucial for the quality and shape of the end product.

Description of the aluminum master model:

Material properties:

Robustness: Aluminum is a suitable material for master models due to its strength and stability. It can withstand the pressure and temperatures in production without deformation or degradation.

Weight: Despite its stability, aluminum is relatively light, which facilitates handling and assembly.

Thermal conductivity: Aluminum can conduct thermal energy well, which can be an advantage in autoclave production in order to achieve uniform temperature distributions.

Production of the master model:

Precision techniques: The model is often produced using CNC machines to ensure the precision and detail of the design. CAD software is used to perfect the design before physical production.

Surface finishing: The surface of the model is treated so that it is extremely smooth to guarantee a high-quality shape with an excellent finish.

Function of the master model:

Mold template: It is used as the main reference in the production of negative molds made of carbon or other composite materials. The precise reproduction of the mold is crucial for the consistency and quality of the parts produced.

Reusability: One aluminum master pattern can be used to make multiple molds, making it a cost-effective option.

Autoclave process:

The molds produced are used to manufacture composite materials under high pressure and temperature in autoclaves. Aluminum as a master model guarantees high accuracy of the moulds.