The Process

The following is an example of a simple component to demonstrate the process of tool making with AE-T-Consulting. Our goal is to make the entire process as flexible and efficient as possible without omitting the necessary, quality-assured milestones. Optional services such as component construction, spare parts production, photo documentation etc. are of course also possible. 

Step 1: Basic input

As input we usually need 2D component drawings with material specification, a 3D CAD model and the tool specification to guarantee compatibility with existing injection molding machines, their connections and clamping systems as well as steel requirements. For simple components, a 3D CAD model with material specification as well as tool specification is generally sufficient. If the tool is not intended for your own use and only components are required, the approximate number of pieces is sufficient and a tool specification is not necessary. After examination, it is also possible under certain circumstances to create a tool using a physical sample or a hand-drawn sketch with basic or critical dimensions. In this case, we first carry out the component modeling and drawing creation before the tool design and let you briefly confirm this. 

Step 2: Tool design

After analyzing the starting material and clarifying all open questions, we start with the tool design in 2D and as a 3D model. Depending on the complexity of the component and the number of cavities, we also carry out a Moldflow analysis as required and add it to the tool design for approval.

Step 3: Tool manufacturing

After the approval of the tool design we start with the actual production of the steel tool. For example, it is possible to only manufacture a single core in our standard forms for samples, small series or prototype tools. This reduces cost and time.

Step 4: Sampling

Once the tool production has been completed and the first components have been successfully shot, we start the sampling process. Sampling content and scope have already been aligned with you in step 1 and can range from simple measurements of the main dimensions to installation tests and an initial sample release according to i.e. PPAP. You will receive the first sample test report in German or English as well as attached samples by Express mail. 

Step 5: Tool or part loading

The last step depends on the type of the tool you ordered. Serial tools will be prepared for shipping (based on the approval of the samples) and will be sent to you by sea freight or in urgent cases via air. In very urgent cases, we also offer to produce a small series of parts and send them to you in advance or parallel to the tool. For prototype tools or those which are not intended for transport, the production and dispatching of the required number of pieces begins. We use local material for this purpose or use materials sent to us at your request. Whether you have ordered parts or a tool, transportation as well as customs and other fees are all included in the price you see.