Manufacturing Process
A screen, phototool, stamping die, casting die, and injection mold require very different levels of engineering and tool construction.
01
What We Keep on File for Every Reorder
After approval, the production information used to make your part is kept on file as the reference for future orders. Depending on the construction, this can include:
| Production Record | Examples |
|---|---|
| Tooling | Dies, molds, screens, and other part specific tooling |
| Drawings | Dimensions, tolerances, geometry, relief, and construction |
| Artwork | Logos, graphics, typography, and positioning |
| Materials | Material type, grade, thickness, and other specified requirements |
| Finishes & Color | Surface treatment, appearance, and approved color references |
| Attachment | Adhesive or mechanical attachment requirements |
| Packaging | Protective film, individual packing, and other handling requirements |
03
Not Every Part Requires New Tooling
Tooling requirements depend on the manufacturing method, geometry, construction, and whether suitable production tooling already exists. Some parts require dedicated dies, molds, screens, or forming tools. Others can be produced with little or no new hard tooling.
New Tooling May Be Required
- Custom stamped or embossed geometry
- Custom die cast shapes
- Injection molded components
- Deep formed or coined parts
- Custom holes, cutouts, or profiles requiring dedicated dies
- Raised or recessed dimensional features
New Hard Tooling May Not Be Required
- Etched parts produced from digital artwork or phototooling
- Printed parts using screens or other relatively low cost setup tooling
- Flat parts that can be cut without a dedicated production die
- Parts compatible with an existing stock die
- Certain simple formed parts using existing tooling
- Designs without embossing or custom formed geometry
Stock Tooling
If an existing die already matches the required shape and dimensions, new cutting tooling may not be necessary. This is most practical when the design does not require custom embossed, recessed, or formed geometry.
04
Tooling Depends on the Manufacturing Method
Different manufacturing methods require different types of production tooling. The tooling itself, the initial investment, and the time required to develop it can vary substantially from one process to another.
| Manufacturing Method | Typical Tooling | Relative Investment | Relative Development Time |
|---|---|---|---|
| Injection Molding | Mold — soft or hardened production tooling | Higher | Longer |
| Die Casting | Casting die / mold | Higher | Moderate to longer |
| Stamping / Embossing | Cutting, embossing, and/or forming dies | Moderate | Moderate |
| Forging / Coining | Forging or coining dies | Moderate to higher | Moderate |
| Forming | Forming dies, fixtures, or dedicated form tools | Low to moderate | Short to moderate |
| Etching | Phototooling and process setup | Low | Short |
| Screen Printing | Screens, fixtures, and process setup | Low | Short |
| Electroforming | Master, mandrel, or process-specific tooling | Varies | Varies |
Relative investment and development time are general comparisons, not quoted costs or lead times. Final tooling requirements depend on the part size, geometry, tolerances, construction, production volume, and required tool life.
05
What Determines Tooling Cost?
Tooling cost reflects what has to be built to produce the part reliably. A simple screen or phototool may require relatively little investment, while a complex mold or multi-operation die can require substantially more engineering, machining, and tool life.
Part Size
Larger parts generally require larger tools, more tool material, and more machining, which can increase the initial tooling investment.
Geometry & Complexity
Deep relief, fine features, undercuts, tight tolerances, complex contours, and difficult forming requirements can increase tooling complexity.
Number of Operations
Some parts require separate cutting, embossing, forming, coining, or other tools rather than one production operation.
Production Volume
Expected quantity and reorder frequency help determine the appropriate tool construction, cavity count, and level of production durability.
Expected Tool Life
A tool intended for limited production does not always need to be built the same way as tooling expected to support years of recurring high-volume orders.
Tooling is quoted against the actual part and production program. Final cost depends on the manufacturing method, geometry, tolerances, expected volume, and the type of tool required.
05
Tooling Should Match the Production Program
The right tooling choice balances initial investment with the expected production requirements. Soft tooling can be a practical solution for limited runs, pilot production, or development work, while harder production tooling is generally better suited to long-term, recurring, high-volume programs.
| Consideration | Soft Tooling | Hard Tooling |
|---|---|---|
| Typical Construction | Aluminum or lower-duty tool construction, depending on process | Hardened production tool steel or other high-durability tooling |
| Initial Investment | Lower initial investment | Higher initial investment |
| Tool Life | Shorter tool life suited to limited or lower-volume production | Longer tool life suited to recurring or high-volume production |
| Tooling Lead Time | Generally shorter | Generally longer |
| Best For | Pilot production, bridge tooling, test runs, and lower lifetime quantities | Long-term programs, recurring orders, high volumes, and extended tool life |
| Long-Term Tradeoff | Lower upfront investment, with greater potential for maintenance or replacement as volume increases | Higher upfront investment, offset by durability and stronger long-term production economics |
Tooling should be selected based on expected production volume, reorder frequency, required tool life, and total cost of ownership — not just the lowest initial tooling quote.
Soft and hard tooling are general production terms. Available tool materials, construction, expected life, and lead time vary by manufacturing method, part geometry, tolerances, and production requirements.
06
Tooling & Sample Lead Times Vary by Process
Tooling and sample development do not follow one universal lead time. Screens and phototooling can often be prepared and sampled faster than machined dies and molds. As tooling complexity, cavity count, tolerances, trial requirements, and validation increase, lead time generally increases.
Typical Tooling + Sample Lead Time
4–5 Weeks
These are relative comparisons, not quoted lead times. Actual timing includes tooling development and initial sample production and depends on the manufacturing method, geometry, cavity count, tolerances, tool construction, required adjustments, and approval requirements.
Screens / Phototooling
ShorterRelatively simple setup tooling that can often be prepared faster than machined production dies or molds.
Simple Cutting Dies
Short to ModerateSimple profile or cutting dies generally require less engineering and machining than more complex forming tools.
Stamping / Forming Dies
ModerateEmbossing, forming, coining, and multi-operation tooling can require additional machining, fitting, and trial work.
Die Casting Tooling
Moderate to LongerCasting dies typically require more extensive machining and process preparation, particularly as geometry becomes more complex.
Injection Molds
LongerMold design, cavity construction, cooling, ejection, finishing, and validation can make injection tooling one of the longer tooling-development paths.
These are relative comparisons, not quoted lead times. Final tooling development time depends on the manufacturing method, geometry, cavity count, tolerances, tool construction, and any required sampling or validation.
02
Once Approved, It Becomes The Production Standard
Once a specification is approved, it becomes the reference for future production. Documented requirements are carried forward from order to order unless a change is identified, reviewed, and approved.
Approved reference
Production is based on the approved drawing, artwork, material, finish, attachment, and other documented requirements.
No silent substitutions
A material, finish, adhesive, or process is not quietly substituted simply because another option is easier to source.
Same standard on reorder
If nothing has changed, the next order is produced against the same approved production record.
Locked does not mean unchangeable. It means nothing changes without being identified as a change.
03
Nothing Changes Without Review and Approval.
When a change is requested, it is reviewed against the existing approved production record before anything is updated. We determine what the revision affects, document the change, and identify any tooling, production, or approval requirements before the revised specification is released.
The requested change is identified against the current approved specification.
We compare the request with the existing drawing, construction, materials, finish, attachment, and other applicable requirements.
We identify whether the change affects tooling, artwork, processing, cost, lead time, or approval requirements.
Updated documentation or a new first article is completed where required before the revised specification is released to production.
The previous standard is not replaced until the revision has been identified and approved.
04
How Changes Can Affect Tooling and Reapproval
Not every revision has the same production impact. Changes to dimensions or geometry may require new tooling and reapproval, while changes to finish, color, adhesive, or packaging may not. Each request is reviewed against the existing approved specification before requirements are confirmed.
| Requested Change | May Affect Tooling? | May Require Reapproval? |
|---|---|---|
| Overall dimensions | Yes | Yes |
| Raised or recessed geometry | Yes | Yes |
| Artwork | Sometimes | Sometimes |
| Material | Sometimes | Yes |
| Finish | Usually not | Sometimes |
| Color | Usually not | Sometimes |
| Adhesive | Usually not | Sometimes |
| Packaging | Usually not | Usually not |
These are general guidelines. Final tooling and reapproval requirements depend on the part, manufacturing method, and scope of the requested change.
05
Not Every Change Requires New Tooling
May Require New Tooling
- Overall size or profile changes
- Hole or cutout location changes
- Raised or recessed geometry changes
- Embossing or debossing changes
- Changes to formed geometry
- Certain construction changes
Typically Does Not Require New Tooling
- Certain color changes
- Certain finish changes
- Adhesive changes
- Packaging changes
- Some printed artwork changes
- Changes that leave the tooled geometry untouched
Tooling impact depends on the manufacturing method and the specific revision. We review requested changes against the existing construction before determining whether new tooling is necessary.
10
Placing a Reorder Is Deliberately Simple
Everything from your original order is retained and controlled—your artwork, tooling, specifications, materials, finishes, and part geometry. Reordering is simply a matter of confirming a few key details so we can prepare the repeat order against the approved production record.
Your PO or Prior Order Reference
Provide your purchase order number or a reference from your previous order.
Quantity
Confirm the quantity you need.
Requested Delivery Timing
Let us know your required delivery date or timeframe.
Confirm or Note Any Changes
Confirm that nothing has changed, or note any revisions to be made.
Once we receive your reorder, we retrieve your retained production record, confirm current pricing and lead time, review any revisions, and proceed using the approved production reference.
Your approved artwork, tooling, specifications, and part information are retained as the production reference for future reorders.
ACROSS OUR PRODUCT RANGE
Different Parts. Different Material Requirements.
Badges, nameplates, labels, overlays, trim, faceplates, and functional components place different demands on material and finish. The right combination depends on the part, its environment, appearance, and service requirements.
BadgesMetal and plastic constructions selected for appearance, relief, finish, and attachment.
TagsMaterials selected for identification, durability, serialization, and operating environment.
LabelsMetal and printed constructions for branding, compliance, and product identification.
Industrial NameplatesMetals and finishes selected for durable data and rating identification.
Decorative TrimMaterials and finishes chosen to integrate visually with the finished product.
Functional ComponentsMaterial selection driven by strength, fit, wear, and functional requirements.
Graphic OverlaysPolycarbonate and polyester constructions matched to graphics, environment, and interface use.
Control Panels & FaceplatesMetal and plastic constructions combining openings, graphics, finish, and durability.
NEXT STEP
Not Sure Which Material & Finish Fit Your Part?
Send us the part, application, environment, expected volume, and any material, color, or finish references you already have. We will narrow the compatible options and recommend the combination that fits the part without adding cost or complexity it does not need.
Request A Quote
Drawings, samples, photos, and color references welcome.