8 Myths About Aluminum Tooling

Aluminum tooling has long been misunderstood in the world of injection molding. Contrary to popular belief, aluminum is not just for prototypes and low-volume production. Modern aluminum alloys such as 7075, Alumold, QC-10, and Hokotol are incredibly durable, often outlasting expectations with runs exceeding 100,000 to 1,000,000 parts.

These myths, like limitations on resin types, production quantities, surface finishes, and tooling costs, stem from outdated perceptions. In reality, aluminum tooling offers robust, versatile, and cost-effective solutions suitable for both prototypes and high-volume production.

Consequently, aluminum tooling is not only viable for high-volume production but also offers cost savings and faster turnaround times compared to steel.

Myth #2: Limited Resin types can be used in an Aluminum mold prototype

The truth is that unfilled resin types like ABS, Nylon, Polycarbonate, and Polypropylene are easier on aluminum molds. But high-temperature resins like Ultem and Vectra to name a few can be used also with success.

Even abrasive resins such as glass-filled types can be used. In the case of abrasive resins, care just needs to be taken to avoid excessive wear by using a hardened aluminum alloy like the above-mentioned 7000 series, QC-10, or Hokotol which all hold up extremely well due to their durability.

If the volume requirements are needed in glass-filled or abrasive resins, options are available in the aluminum mold such as, case hardening of the aluminum with successful known processes such as anodizing, plating, or inserting certain areas of aluminum with steel.

Myth 3: Aluminum cannot be used for production quantities

How does 100,000 to 1,000,000+ production-quality plastic parts sound?

Not exactly short-run or low-volume! For many projects this is more than enough for the entire project until the next design change or upgrade.

Higher production quantities can be achieved depending on the resin and design. Aluminum tooling is also perfect for keeping marketplace share when bridge tooling is needed to produce plastic parts until the production tool is finished. An added benefit is that is the tool life is exceeded, aluminum is forgiving and easy to maintain and enhance in order to get those last few plastic parts until the hardened steel production tool is ready.

It’s very rare to find a finish that cannot be applied to aluminum. This myth may come from small closed-in features on a design where it’s difficult to apply texture. Or the extra handwork required in polishing highly aesthetic surfaces like those for optical components, chrome plated, or any other texture finish that requires an ultra-smooth finish that is touched and seen by the consumer that might be more work than some rapid tooling shops specialize in.

Myth #5: Aluminum tooling process issues isn’t optimum for potential process issues

Nothing is worse than all the random gremlins that can plague a steel or aluminum alloy tool. Aluminum’s greater thermal conductivity can reduce or eliminate the most common process issues with molds. Aluminum’s nature allows for heat distribution which leads to a more even part fill with no hot or cool spots.

An aluminum tool also cools evenly which keeps a part’s integrity and protects it from shrink warpage.

The thermal conductivity of aluminum alloys has been proven to substantially reduce cycle times; which directly translates into lower costs and faster parts. The high strength of these aluminum alloys is due to their being developed initially for the aerospace industry and the need for quality consistent metals.

30,000 feet in the air is not the place to find out that the dimensional stability of your aluminum is not uniform in strength.

Myth #6: Tool modifications to soft tools like aluminum molds are too difficult and expensive

Aluminum couldn’t be more accommodating to design changes or to troubleshooting possible production issues. Internal issues like gate locations to insert redesigns, and making changes are not as much of an issue as a steel alloy would be due to its forgiving softer nature.

This is also true for the actual design because making minor modifications and tweaks is rather easy and cost-efficient.

Myth #7: Aluminum tooling cannot handle complex designs

Good design needs to be incorporated with good manufacturing. Both are co-dependent upon each other.

Modern aluminum alloys and advanced machining techniques enable the creation of intricate and detailed molds. Aluminum’s excellent machinability allows for precise and complex geometries, making it ideal for producing detailed parts with tight tolerances.

Furthermore, aluminum’s superior thermal conductivity aids in achieving consistent and high-quality surface finishes, debunking the myth that it’s only suitable for simple designs.

Additionally, its machinability allows for quicker and cheaper mold production, which can be especially beneficial for projects requiring rapid turnaround. When considering these factors, aluminum tooling often proves to be a more economical choice in the long run.

Summary

The myths surrounding aluminum tooling often stem from outdated perceptions. Modern aluminum alloys, like 7075, Alumold, QC-10, and Hokotol, prove that aluminum is not only for prototypes but can handle high-volume production runs, complex designs, and a wide range of resin types.

These materials offer excellent thermal conductivity, cost savings, and efficiency improvements, making aluminum a viable and economical choice for both prototype and production tooling. By debunking these myths, we can appreciate aluminum tooling’s robust, versatile, and cost-effective nature.

Interested in learning more about using aluminum tooling on your next project? We’re here to answer any questions you have!