What Is The Average Length Of Time To Create Tooling?
For simple thermoforming tools and one die cutting plane, tools can be made in 2-3 weeks. For complex thermoforming shapes and multiple die-cutting planes, anticipate 4-6 weeks. If the design does not change, prototype tooling can be used for production tooling.
- How Long Will Tools Last?
A thermoform tool will have a life comparable to the production run of the electronic product, in most cases. This is due, in part, to the low thermoforming temperatures. Die cutting tools do not have the same life and their life depends upon the film, part tolerances, and tool materials. Short runs (<10,000 parts) with simple designs can be done with steel rule dies. Longer runs and more complex cuts may require more than one set of die cut tools depending upon tolerances.
- How Expensive Is The Tooling?
Relatively speaking, the tooling for Form/Met is very low cost. An average set of tools (thermoforming and die cutting) for a simple part would run from $2,000 to $10,000 and be adequate for 50,000 parts on average. More complex thermoforming tools with complex multi-axis die cutting could run to $40,000. Generally, our experience has been that tools will cost between $5,000 and $20,000 for production lives that stretch into the hundreds of thousands.
- What Are The Cost Drivers For The Tooling?
The primary cost driver is the number of planes of cutting required. The more planes, the more tools. One-dimensional cuts (i.e., the 1st cut) to separate the basic part from the web can be done in-line and is thus not very expensive. Multiple plane cuts require that the 2nd cut and subsequent cuts be done off-line adding to the cost. Polycarbonate thermoforming tools are more expensive (1.2X to 1.5X) because the film materials must be more uniformly heated thus necessitating a more elaborate tool design and controls. Die cutting tools are also a bit more expensive due to the tougher character of PC.
- Is there maintenance or service of any kind required for the tooling?
Generally, "No." If production runs extend beyond the original estimated tool life span, the OEM customer will be advised of the need for a new set of tools.
- Where is the tooling stored?
Tools are stored at the WaveZero manufacturing facility located in Elk Grove Village, Illinois (a suburb of Chicago, IL)
