An innovative new service from Oxfordshire-based injection moulding specialist OGM (www.ogm.uk.com) has been introduced to reduce the lead time for producing mould tooling by up to 50%.

Based on a combination of conventional subtractive machining and the latest additive-manufacturing processes, the new Rapid Production Mould Tools (RPMT) service is said to enhance the quality and finish of most types of mould-tool inserts (traditionally made using conventional CNC machining techniques).

The lead time for a new tool set produced in the Far East is said to be typically 12-14 weeks; the hybrid RPMT technology can cut that by four to six weeks.

This has been achieved by using standard modular tool components, such as bolsters, blank inserts and ejector sets, which are CNC-machined and drilled to create a substructure with the appropriate cooling channels and fixtures.

OGM then uses a direct metal laser sintering (DMLS) system to add custom-designed mould inserts to the standard tool base.

Extremely complex mould shapes can be produced in a matter of hours, with a high-quality surface finish — and in a variety of materials, including steel, stainless steel and Inconel — to create tool sets capable of withstanding extended use.

The system can also be used to repair or modify tool inserts quickly and efficiently.

Paul Wightman, OGM’s managing director, said: “By taking this hybrid approach to the challenge of mould tool production, we are able to help customers compress lead times and produce a new generation of high-quality complex inserts that give them increased design freedom.

“The significant investment we have made in new DMLS technology means that we can offer a service that is both quick and competitive. Companies no longer need to offshore their tool production; we can do it faster, better and at similar cost in the UK.”