Search Now

Product Design:

Tool Concept

If you’re under pressure to source a strong, lightweight and well-designed component, whilst sticking to a tight budget and timescale – DLS Plastics can help. Our customers often approach DLS with a problem - perhaps a new bracket or fitting that needs designing and manufacturing and is difficult or impossible to source elsewhere, or maybe a problem where even our customer is unsure of a suitable solution. The design team at DLS Plastics have been creating innovative designs and solving complex engineering problems for over 40 years. We are able to provide support right from the earliest design stages and are happy to work with your design teams, buyers and end users to ensure you are getting the best possible solution. Drawing upon our 40 years’ experience as mould toolmakers, we help highlight any areas that could potentially create issues in manufacture. We’ll also suggest improvements and modifications to streamline proposed production routes, resulting in more cost effective and innovative tooling as well as reducing product development time.

Product Design

Fully understanding your requirements and timescale is vital to the success of a project. The design team at DLS will hold discussions with all involved parties to understand and agree all the relevant project details. We are happy to create all designs in house ourselves, or alternatively can interpret and work from your own designs. We are also able to accept and interpret commonly used industry standard CAD data, consisting of:
Iges - 3D
Step - 3D
Sat - 3D
Stl - 3D
DXF - 2D
DWG - 2D

If your system does not support any of these software types, we’ll work with you in any format you require, and then transfer to our supported file types further down the line as part of the design work. Once all the necessary information is collected, our designers produce initial component designs. The designs are then reviewed and any adjustments or enhancements are made before a final design is created. At this stage the final design is approved with the customer and signed off. Our design team then take this finalised design and convert it into a complete working design ready for material ordering and efficient part manufacture.

Mould Tool Designs

Here at DLS we utilise Cimatron Software, to provide information for all elements of the tool design process. This, paired with our in house mould flow software, allows us to gain optimum fill, flow and gate detailing where necessary. This means that you can expect multiple cost savings, not only from reduced material wastage, but also from reduced moulding time. It also saves on development time, something that we know is important to you when releasing a new product.

Fully detailed assembly drawings are provided as standard as part of a project pack for all tools produced. This is issued to our in house toolmakers at the time of production as well as being available to the customer so that they can gain a better understanding of the processes involved. All information and processes are compliant to ISO 9001, so you can be sure that all procedures and services are provided to the highest standard.
We use only high-grade materials sourced from some of the UK's biggest stockholders, mostly tooling in aircraft grade Aluminium and also P20 steel.

Although aluminium tooling is generally regarded as relatively low volume shot capability, our experience in this field and our design and mould manufacturing methods means that we’ve historically been able to produce engineering polymer parts from aluminium tools that have exceeded 100,000 parts. DLS Plastics can also optimise tooling designs to work with Bolster systems, meaning tools can be fitted, run for moulding and removed in a much shorter timescale compared to tradition tooling.

Rapid Prototyping

3D Printing Materials and Processes

3D Printing is the latest development in rapid prototyping. This means that 3D solid items can be produced in a very quick timescale to give a true representation of a finalised product. This is most helpful in applications where design teams are unsure of final details both in terms of dimensions and aesthetics. The majority of materials used in industrial 3D printing are polymers. However, recent developments for certain applications have seen metals, alloys and ceramics being utilized in melting or sintering processes. Two of the most prominent 3D printing processes available to DLS Plastics Customers are:

Stereolithography (SLA)

A 3D design is exported to a 3D printer where an epoxy resin reacts with a laser beam and hardens to form extremely accurate solid parts layer by layer. Several different materials are available, dependant on our customers’ requirements for the prototype.

Selective Laser Sintering (SLS)

Unlike Stereolithography, Selective Laser Sintering works with powdered materials (not resin), a laser beam fuses powder particles together to reflect 3D data as designed. The key advantage of this type of 3D printing is that parts can be produced in Nylon 12 PA650 or PA615-GS (Glass Filled) – this provides a more true to life representation of a finalised nylon product as well as increased strength.

If you have a new project or an existing product you are looking to resource or modify, get in touch with our sales team now on 01476 564549, or fill out our Contact Form.

Need Help?
need help? Call or email us now. For all enquiries please feel free to contact a member of our staff using the details below:
+44 (0)1476 564549
+44 (0)1476 567538
[email protected]