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Tooling

Merit Technology has the most modern equipment available in the plastic processing industry. Including a state of the art tooling department. All molds are made to the customer's exact specifications. Molds are made of Steel or Aluminum. These molds are cut using precision CNC machining.

We manufacture molds exclusively using advanced aluminum alloys and high-speed CNC machining. No steel, EDM or expensive custom engineering. We work in almost any engineering resin, which means the parts can support functional testing, bridge tooling or even ongoing production requirements for many applications. Our entire process features an unprecedented degree of standardization and automation, which is how we deliver injection molded parts faster and more economically than ever before possible.

Merit Technology has been a leader in developing innovative, non-traditional tooling methods for 10 years.
• Turn around time as fast as 72 hours
• Quotes in one day or less

• Tool Life 500 to 2,000 parts
• Customer Confidentiality

Part Geometry's
• Difficult or Irregular Contours
• Irregular or Steeped Parting Line
• Complicated Shut Offs and Undercuts
• Zero Draft Angles
• Surface Finish - High Polish to Textured

Tool Features
• Customer selected Resins
• Excellent Seal Off For Overmolding
• Short run and production molding available

Rapid Tooling

In today’s competitive marketplace, speed -- like winning -- isn’t everything, it’s the only thing. Rapid tooling can compress your time to market even further and reduce your tooling costs at the same time.

In addition, rapid tooling techniques (such as composite tooling) give us the ability to create parts with actual end-use production materials and run quantities up to production volumes, meaning more parts per mold.
In fact, these rapid tooling techniques bridge the gap between Room Temperature Vulcanized (RTV) silicone rubber molds, and machined aluminum tooling. Not only can you create longer runs of functional prototypes or pre-production samples in a wider range of materials; you can also conduct manufacturing analysis or field trials with fully functional parts. This enables you to finalize selection of production materials and verify the tool prior to final mold making.

For the foundry industry, rapid tooling offers a fast, cost-effective alternative for producing multiple investment casting wax masters.

We manufacture molds exclusively using advanced aluminum alloys and high-speed CNC machining. We work in almost any engineering resin, which means the parts can support functional testing, bridge tooling or even ongoing production requirements for many applications. Our entire process features an unprecedented degree of standardization and automation, which is how we deliver injection molded parts faster and more economically than ever before possible.Idea for time constrained and low volume projects Merit Technology’ rapid tooling services can convert data to running tool in as little as 10 days. Rapid tooling materials such as composite resin, aluminum and soft steel give you a wide selection to meet part number requirements within your constrained time frame.

What Is Rapid Tooling?


Rapid tooling is using a rapid prototype, either indirectly or directly, as a tooling pattern for creating a mold. Rapid tooling techniques enables you to have molds that supply prototype parts with the correct material at a substantially reduced cost in a fraction of the time it takes to produce parts from production tooling processes. The greater the complexity of the part, the greater the benefits of cost and time.


Rapid tooling starts with either an SLS or an SLA (finished to level 4) model of your part. The model is used to design the mold, taking into account the following considerations:
• Optimum molding angle and parting line for the part
• Size of the mold
• Determination if metal retainer or "chase" is required
• Incorporation of "locks" to prevent shifting of core and cavity
• Determination of the size and location of spruem runners, and gates
• Specification of the ejection required, if any
• Determination of the size, number, and location of water lines for temperature control, if required
• The efficiency and number of parts that can be produced from composite tools is limited by the size and complexity of the parts combined with the strength and heat resistance of composite materials available, in some cases up to 3000 parts have been made.

The term Rapid Tooling (RT) is typically used to describe a process which either uses Rapid Prototyping (RP) model as a pattern to create a mold quickly or uses the Rapid Prototyping process directly to fabricate a tool for a limited volume of prototypes. RT is distinguished from conventional tooling in that:
a) Tooling time is much shorter than for a conventional tool. Typically, time to first articles is below one-fifth that of conventional tooling.
b) Tooling cost is much less than for a conventional tool. Cost can be below five percent of conventional tooling cost.
c) Tool life is considerably less than for a conventional tool.
d) Tolerances are wider than for a conventional tool. We do not intend to comprehensively cover all types of RT in this narrative. In addition to Silicone Rubber Molding (SRM), we present Composite Molding and Direct AIM (ACES Injection Molding). The field of RT is expanding rapidly and information on many of the new methodologies is still changing.

Low Volume Tooling / Bridge Tooling

In low volume niche markets the time and cost of production tooling isn’t always justifiable. CNC, SLS and Cast Urethane procedures can offer a cost-effective alternative without sacrificing quality.

Low Volume Production parts enable manufacturers to bring products to market without the time and expense of production tooling. In many specialized industries such as aerospace and medical equipment, annual production volume does not justify the expense of production tooling. Low Volume Production parts from Merit Technology allow manufacturers to ship products earlier and to produce high-quality products at a lower overall cost. With Low Volume Production parts, design modification can be incorporated at a fraction of the time and cost associated with changing production tooling.

Merit Technology produces Low Volume Production parts using SLS, CNC, and Cast Urethane technologies, depending on the specific requirements. Low Volume Production parts can be produced in as little as five working days.
Merit Technology' customers use Low Volume Production parts to:
* Ship products when production tooling is delayed
* Produce high quality products in limited quantities
* Accelerate the delivery of product revisions
* Produce customized products

High Volume Tooling / Production Tooling

Merit technology’s investment into high-cavity automated systems provides our customers with an industry leading efficiency. We understand that quality is no less important then (speed) and because of this Merit technology closely monitors ever step of the production process holding to strict tolerances and unrelenting protocol.

At Merit Technology, we are more than capable of meeting your high volume tooling and manufacturing needs on time and within your budget. When your demands increase, we can boost your production with our high volume tooling capabilities. If you're trying to lower costs or reduce lead times, you can consider our partnerships in Asia.

Tools and components can be manufactured via high speed machining or molding with precision and quality. Outfitted with a state-of-the-art tooling room facility in-house and offshore, we deliver tight tolerance products under stringent timelines. At PPE, strict quality standards carry with them considerable responsibilities. We monitor every step of every project with meticulous care.

Due to the excessive cycles they run, we adhere to a stringent maintenance plan for all high-volume tooling and manufacturing, which provides for quick tooling modifications, ease of component manufacturing, and virtually no downtime when repairs are necessary. Utilizing preventive maintenance for all equipment, keeping our certifications up to date, and maintaining the highest standard of customer satisfaction are just a few of the ingredients to our success in tooling and manufacturing.

Gas Assist Tooling

Experience in several gas assist parts and processes

Examples
★ Seat base with handle with assembled chrome accent piece
★ Handles
★ Lids
★ Bumpers (snowmobiles)

 

Export Tooling

High quality economic tools exported for us production. By exporting your tooling you can save up to 70% off the domestic price. Our tools are designed and guaranteed to fit in any injection molding equipment your locally based facility uses.

Custom tooling for export to the U.S. and other countries is becoming more popular. Merit Technology builds a large portion of its custom design tools for export. Our clients have found that they can save 50-70% on tooling by having us manufacture the tools for them in China and export them to their facility, a local plastic shop, or our plastic injection molding facility. By making the molds in China customers can reduce their initially investment substantially, and allocate that revenue towards extra inventory if they choose.

Merit Technology ensures 100% satisfaction on our tools. Detailed drawings are provided for customer approvals, and we always provide prototypes for first article approval prior to packaging and shipping the tools. Custom tools are also designed to fit in whatever injection molding equipment our customers or their suppliers might have. Those dimensions are obtained from our customers prior to finalizing pricing and drawings.

Send us your next custom tooling project for a free reference quote from our factory. We guarantee you will be impressed with the quality and savings!

Our warehouse and logistics centers in Shenzhen China (just inside the border from Hong Kong) can make sure all of your delivery needs are met. From our China mold makers location we are able to ship to any locations in the world. We have routine shipments of containers coming into the central United States in order to provide competitive pricing on large orders. Please call to determine the large shipment transit time to your city.

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Tel: +86-755-27404667   Fax: +86-755-27404914
Add: 409, Guangming Street, Guangming new District, Shenzhen, China