Agile Manufacturing for Small Series
Prototype molds are the perfect tool when you need real injection-molded parts without waiting weeks or investing a fortune in tooling. We are talking about obtaining between 50 and 5,000 functional parts in final material (PA, POM, HDPE, ABS, polypropylene, even flame-retardant materials) in just 3 to 4 weeks instead of 8 or 10.
At ProtoSpain, we understand that every minute counts. While your competitors are still waiting, you already have injection-molded parts in your hands, performing assembly tests, validating with end users, discovering issues before they become costly to fix. That agility makes the difference.
Prototype molds are not “low-quality molds” nor “reluctant shortcuts.” They are an engineering solution expressly designed so you can iterate without limits during the validation phase, knowing that the parts you hold in your hand are exactly identical to those that will come out of a production mold. Same materials. Same functionality. Same reality.
Technical Section: What Exactly Is a Prototype Mold?
Definition and Purpose
A prototype mold is an injection tool manufactured in aluminum (typically Al 6061-T6 or similar) with a simple cavity (generally one part per cycle), designed to produce between 500 and 10,000 parts with acceptable precision before requiring maintenance or major repair.
It is not a “temporary experiment.” It is a professional tool, precision-machined (cavity tolerances ±0.05 to ±0.1 mm), ready to inject under normal production conditions: pressures of 700 to 1,200 bar, material temperatures between 220 and 280 °C (depending on the polymer), cycles of 15 to 60 seconds.
Mold Materials:
Hardened Aluminum (H13 or equivalent):
- Fast machining: a prototype mold is manufactured in 1 to 2 weeks in our 5-axis CNC centers.
- Excellent thermal conductivity: cooling channels (drilled or 3D-machined) cool the part faster, reducing injection cycle time.
- Sufficient hardness for non-highly abrasive plastics (PA without glass fiber reinforcement, ABS, PP, PE, POM).
- Cost 60–70% lower than hardened steel molds, freeing budget for more iterations.
Limited steel in prototypes:
Although we use small hardened steel inserts in very critical areas (example: threaded holes that will rotate, continuous friction zones), most of the mold is aluminum for speed.
Prototype Mold Manufacturing Process
Phase 1: Design Analysis (2–3 days)
You send your CAD model. Our mold engineers analyze it:
- Part ejection: we identify demolding direction, draft angles, gate location.
- Thermal flow analysis: we simulate (Moldflow or similar) to optimize cooling channel thickness and injection point position.
- Risk identification: areas with potential flash, sharp corners, thin walls that may not fill.
- DFM design recommendations: without modifying your part, we suggest where to add small angles, radii, or draft to improve manufacturability.
Result: design approval, technical mold drawing in CAD.
Phase 2: Mold Machining (7–10 days)
- Raw aluminum block: typically 200 × 150 × 120 mm (adapted to part size).
- Cavity milling: 5-axis CNC centers. Geometry is machined directly from the CAD model, with tight tolerances.
- Cooling channel drilling: water at 20–30 °C circulates through channels (typical diameter 8–10 mm) to evacuate heat.
- EDM (if applicable): for internal details impossible to mill (e.g. very deep channels, sharp inaccessible corners).
- Polishing and preparation: cavity surfaces are polished to Ra 0.8–1.6 µm depending on desired finish.
Phase 3: Assembly and Adjustments (2–3 days)
- Base plate and ejectors: the mold is fitted into a standard mold base (HASCO, DME or equivalent) with pneumatic ejectors to release the part after each cycle.
- Dimensional calibration: we measure the final cavity using CMM (coordinate measuring machine).
- Opening/closing tests: we verify smooth opening/closing and correct ejector operation.
Phase 4: Trial Injection (2–5 days)
- Injection machine calibration: pressure, temperature, and cycle time are adjusted for your specific material and part.
- Initial T0 run: first 10–50 parts. We observe:
- Are all part cavities filling?
- Is there flash, air traps, sink marks?
- Is the cycle stable or do pressures/temperatures fluctuate?
- Are dimensions within specification?
- Iterative adjustments (T1, T2…): parameters are modified or, if necessary, the cavity is lightly re-machined.
- Approval: when we obtain 10 consecutive OK parts, the mold is approved.
Total time from CAD to first parts: 2–3 weeks. That is what you achieve with a prototype mold. That’s what you get with a prototype mold.
Differences Between Prototype Molds and Series Molds
Prototype molds vs. series molds present the following differences:
PROTOTYPE MOLDS
Durability and Service Life
Prototype mold: Softer aluminum. After 5,000–10,000 cycles, the cavity begins to show signs of wear:
- Slight loss of cavity gloss (minor, usually imperceptible on the part).
- Micro-scratches in high-friction areas (especially if the plastic contains glass fiber or abrasive fillers).
- Small localized flash may appear after many cycles; it is easily removed during manual finishing if necessary.
-
Dimensional Accuracy
Prototype mold: ±0.05 to ±0.1 mm in cavity dimensions.
- Parts typically achieve tolerances of ±0.1 to ±0.2 mm (depending on plastic, geometry, injection cycle).
- This is sufficient for 99% of functional validations.
- Surface finishes: Ra 0.8–1.6 µm typical (the “tool mark” is visible under magnification, but functional).
-
Ease of Modification
Prototype mold: The great competitive advantage.
- Small dimensional change: we re-machine the cavity (1–2 days, cost €300–€800).
- Need to close a hole that was poorly designed: we add a welded aluminum insert and re-machine it (2–3 days, €400–€1,200).
- Gate location is not optimal: we redesign, re-machine, and re-test (3–5 days, €600–€1,500).
All of this is done without extremely long lead times or prohibitive costs. That is why the prototype mold philosophy is “iterate, iterate, iterate.”
PRODUCTION MOLDS
Durability and Service Life
Production mold: Hardened steel at 50–54 HRC. Withstands 500,000+ cycles without visible degradation. Some molds reach 2–3 million cycles with preventive maintenance (cleaning, polishing, coolant oil replacement).
Real implication: The prototype mold is “economically disposable” once it has fulfilled its mission. There is no need to repair it, modernize it, or store it indefinitely. Mold components are discarded or the aluminum is reused.
Dimensional Accuracy
Production mold: ±0.02 to ±0.05 mm in the cavity (in many cases ±0.01 mm or better).
- Parts typically come out at ±0.05 to ±0.1 mm (better thermal control, better repeatability).
- Surface finishes Ra 0.1–0.4 µm on critical surfaces (mirror polish if necessary).
- Critical when parts are visible (automotive, luxury, premium electronics) or when they have extreme mechanical criticality (medical implants, aerospace).
- Ease of Modification
-
Production mold: Modifications are heavy.
- If you need to change a hardened steel cavity at 52 HRC, you must de-temper it (remove hardening), machine it again, re-harden it, and verify it again. Minimum 1–2 weeks, cost €2,000–€5,000+.
- Often, it is more economical to manufacture a new insert and fit it into the mold (same lead time, similar cost).
- Minor modifications are limited: incremental clearances are accepted, but not fundamental cavity changes.
For this reason, a golden rule: “only put into the production mold changes that you already validated in a prototype mold.” Do not improvise in series.
When to Use a Prototype Mold?
Clear Differentiation: Prototype Mold vs Production Mold
Aspect | Prototype Mold | Series Mold |
|---|---|---|
Main Material | Hardened aluminum (Al 6061, Al 7075) | Hardened tool steel (H13, 1.2343) |
Hardness (HRC) | 35–40 HRC | 50–54 HRC |
Estimated Lifetime | 500–5,000 cycles; up to 10,000 with maintenance | 500,000–1,000,000+ cycles |
Number of Cavities | 1 cavity (rarely 2) | 2, 4, 8, 16 cavities typical |
Mold cost | €5,000–€15,000 | €50,000–€150,000+ |
Manufacturing time | 2–3 weeks | 8–12 weeks (sometimes more) |
Cavity accuracy | ±0,05 to ±0,1 mm | ±0,02 to ±0,05 mm |
Surface finish | Ra 0.8–1.6 µm typical | Ra 0.1–0.4 µm (critical surfaces) |
Hot runner systems | Simple or no hot runner | Balanced multi-cavity hot runner |
Cooling | Standard drilled or machined channels | 3D conformal cooling, Beryllium-Copper inserts, zone temperature control |
Post-trial modifications | Easy and fast (re-machining) | Costly and slow (usually require new insert) |
Typical warranty | No formal warranty applies | 1–2 year warranty or repair included |
Reusability | Disposable after wear; low economic impact | Recoverable for other productions; investment to protect |
When to Use a Prototype Mold?
Expected volume | Recommended technology | Why |
|---|---|---|
1–50 parts | Vacuum casting / CNC machining | Too few to amortize any mold; more agile techniques |
50–500 parts | Prototype mold | Break-even point: fast and economical mold to validate at low volume |
500–5,000 parts | Prototype mold is optimal | Perfect service life; justified investment; real parts in final material |
5,000–50,000 parts | Transition to production mold (or prototype if budget is critical) | Evaluate case by case |
50,000+ parts | Production mold | Premium mold ROI amortized; maximum productivity |
Technical Capabilities of Prototype Molds at ProtoSpain
Machine Specifications
Parameter | Value |
|---|---|
Maximum part size | ~300 × 200 × 150 mm (depending on geometry) |
Maximum injected part weight | ~200–300 grams (in light PP/PE); less if dense plastic (PA, acetal, ABS) |
Supported materials | PA6, PA12, PP, PE, ABS, PMMA, POM, PC, ASA, PBT, PPC, flame-retardant materials (V0, V1), with/without glass fiber reinforcement |
Cavity Tolerances | ±0.05 mm (standard); ±0.08 mm (without extra CMM control) |
Resulting part tolerances | Typically ±0.1–0.2 mm; depends on material and injection cycle |
Cavity surface finish | Ra 0.8–1.6 µm (standard); Ra 0.4–0.8 µm if specifically required |
Number of Cavities | 1 cavity (standard); 2 cavities in exceptional cases |
Typical injection cycles | 15–45 seconds (depending on wall thickness, material, geometry) |
Estimated Lifetime | 2,000–5,000 cycles (up to 10,000 with care and maintenance) |
Mold manufacturing time | 2–3 weeks from design approval |
Injection pressure | Up to 1,200 bar (aluminum mold withstands well) |
Comparison Against Other Technologies
Prototype Mold vs Vacuum Casting
Aspect | Prototype Mold | Vacuum Casting |
|---|---|---|
Volume | 100–5,000 parts | 10–50 parts |
Material | Injected final material (real PA, ABS, PP) | Simulated polyurethane (similar density and hardness, but not identical) |
Accuracy | ±0.1–0.2 mm typical | ±0.3–0.5 mm (less accurate) |
Accuracy | Direct from mold, very good | Replicates master prototype finish (can be excellent if master was well polished) |
Time | 2–3 weeks mold + injection | 1–2 weeks (faster in total time) |
Unit Cost | Low (€2–€5 per part typical) | Medium (€3–€10 per part) |
Tooling cost | €7,000–€15,000 | €1,000–€2,000 (silicone mold) |
Test validity | Parts are 100% representative of series | Approximate properties; material is not final |
Best for | Design and production validation in final material, short functional series | Fast mockups, aesthetic/initial form tests, very limited budgets |
Prototype Mold vs CNC Machining
Aspect | Prototype Mold | CNC MACHINING |
|---|---|---|
Volume | 100–5,000 parts | 1–100 parts |
Accuracy | ±0,1-0,2 mm | ±0,02-0,05 mm (much better)) |
Accuracy | Depends on mold, typically Ra 0.8–1.6 µm | Very good, Ra 0.2–0.8 µm |
Materials | Thermoplastic plastics | Any metal (aluminum, steel, titanium), rigid engineering plastics |
Complex details | Yes, mold is flexible | Limited to machinable geometry (no complex internal access without angles) |
Production cycle | Fast parts once mold is made (15–45 sec cycles) | Slow part-by-part (minutes to hours depending on complexity) |
Unit cost (low volume) | Medium–Low | Very high (€20–€100 per part if few) |
Best for | Validating plastic parts at medium-low volume | Metal prototypes, unique CNC parts, extreme tolerances |
At ProtoSpain, we work with most commercial thermoplastics:
- Polypropylene (PP): lightweight, good surface finish, low cost. Ideal for prototype molds.
- Polyethylene (PE): HDPE/LDPE, flexible, packaging/container applications.
- Nylon (PA6, PA12): high mechanical strength, tight tolerances; glass-fiber-reinforced nylon (more abrasive, requires care in the mold).
- ABS: rigid, premium finish, automotive/electronics. Excellent for prototype molds.
- Acrylic (PMMA): transparent, optical. Requires a highly polished cavity (Ra<0.8 µm) for clarity.
- Polycarbonate (PC): ultra-resistant, transparent. Long cycles; prototype molds are perfectly viable.
- Acetal (POM/Delrin): excellent dimensional accuracy, technical parts (gears, bushings). Highly machinable, ideal for prototyping.
Flame-retardant materials (V0, V1): electronics and automotive sectors. More expensive materials that require well-adjusted molds; we recommend using a prototype mold for initial validation.
PEEK, LCP, thermoplastic elastomers (TPE), XIMIDEX… Each case is unique. Some injection molding cycles are special (high temperatures, long times, variable pressures). We assess the feasibility of using a prototype mold versus alternatives (machining, vacuum casting).
Available Finishes
After injection, we offer:
- No finish (as-molded): the part comes out of the mold. Gate/feeder marks require manual trimming or machining.
- Manual polishing: removal of flash, smoothing of edges, polishing of critical areas (approximately 4–8 labor hours per batch of 100 parts).
- Painting / Spraying: polyurethane, epoxy, matte/gloss finishes, custom colors (€3–€5 per part + setup, depending on volume).
- Silkscreen printing / Pad printing: logos, text, codes (€0.50–€1.50 per part, minimum volume 100 parts).
- Anodizing (if applicable): very rarely used in prototype molds; performed after CNC machining, not after injection.
Step 1: CAD Submission and Initial Consultation (1 day)
You upload your 3D model (.STEP, .IGES, .CATIA) to our online portal or send it to us by email.
Our team:
- Verifies that it is an injectable part (no impossible undercuts, correct draft angles).
- Identifies potential injection points (where the molten material enters).
- Estimates final weight and required plastic volume.
- Suggests a material if you have not defined one.
Communication: via email or call, we describe findings, recommendations, and send an approximate quote.
Step 2: Design and Quotation Approval (2–3 days)
We confirm with you:
- Material (PA6, ABS, PP, etc.).
- Desired finish (natural, polished, painted, etc.).
- Estimated injection volume (50, 500, 2,000 parts).
- Lead times.
We generate a formal quotation including:
- Prototype mold cost.
- Cost per injected part.
- Mold manufacturing + injection lead times.
- Full delivery time.
Typical example: Prototype mold €10,500 + 1,000 injected parts at €3.50/unit = €14,000 total, delivery in 4 weeks.
Step 3: DFM Analysis and Design Optimization (2–3 days)
If requested (recommended), we perform a Design for Manufacturability analysis:
- We simulate cavity filling (Moldflow, Autodesk Simulation or similar).
- We identify risk points: areas where material may not reach, potential weld lines, bottlenecks.
- We recommend small adjustments (increasing draft angles, smoothing transitions) without altering functionality.
- We optimize the injection point for better flow.
Cost: often included in our mold quotation. In complex cases, analysis cost €500–€1,500 (deductible if you decide to proceed).
Benefit: in production molds, this avoids costly surprises. In prototypes, it simply saves us correction cycles.
Step 4: Mold Manufacturing (2–3 weeks)
While you continue with your project, we:
- Generate the technical mold drawing in 3D CAD (with all dimensions, tolerances, cooling systems, ejectors).
- CNC machining: 5-axis centers cut the cavity in an aluminum block.
- Drill cooling channels and install piping/connectors.
- Assemble into the base plate (standard HASCO) with pneumatic ejectors.
- Perform CMM measurement of the final cavity to verify tolerances.
- Carry out opening/closing tests on the injection machine.
Step 5: Trial Injection (T0, T1, T2…) (2–5 days)
Injection machine calibrated. First parts:
- T0 (initial run): 10–20 parts. We observe filling, overall quality, no critical defects yet.
- Inspection: we measure and inspect dimensions and finish to determine if pressure/temperature/cycle time adjustments are needed.
- T1 (secondary run): 50 adjusted parts. Same injection parameters, quality continuity.
- If everything is OK: approval. If there is a defect, we adjust parameters or lightly re-machine the cavity (rare case).
Step 6: Full Production (7–10 days)
We inject the requested volume (500, 1,000, 5,000 parts). We process batches of 100–500 parts per day (depending on machine, cycle, finishes).
Quality control: each batch is sample-inspected (typical AQL 2.5). Critical dimensions are measured, surface finish is verified, flash is detected.
Step 7: Finishing and Packaging (2–5 days)
As agreed:
- Gate trimming: removal of the gate material “runner.”
- Manual polishing or machining: if required.
- Painting / finishes: if applicable.
- Packaging: cardboard boxes, quality documentation (certificates, sample inspections).
Step 8: Delivery
Shipment via express carrier (DHL, MRW, etc.). You receive the parts at your office/workshop. Documentation included: material certificates, injection reports, verified dimensions.
Case 1: Home Appliance Startup
Scenario: New design of a detergent dispenser for washing machines. Material: ABS. Initial volume: 2,000 units for testing with OEM partners.
Alternatives considered:
- CNC machining: 2,000 parts = 100–150 labor hours, very expensive (€5–€8 per part).
- Vacuum casting: polyurethane, not real ABS; different properties; rejected by the customer.
- Injection with production mold: €80k mold cost, 8–10 weeks, very high investment for the validation phase.
Decision: ABS prototype mold.
- Mold: €9,500. Parts: 2,000 × €2.80 = €5,600. Total: €15,100.
- Lead time: 3–4 weeks.
- Result: Real ABS parts, assembled into prototype washing machines (functional validation), presented to partners.
- Savings: vs production mold, €80k–€100k avoided. vs machining, €5–€8 per part avoided (€10k–€16k savings on 2,000 parts).
- After success, injection data is transferred to the production mold. The prototype mold is discarded. Full life cycle: mission accomplished.
Case 2: Class IIa Medical Device
Scenario: Assembly of plastic components for a medical sensor. Material: transparent PC + black PA6. Volume: 500 units for clinical validation and CE certification.
Challenge: Critical fit precision (tolerance ±0.1 mm); perfect transparency in PC (optical finish).
PC + PA6 prototype mold:
- Two simple molds (one per material).
- Cavities optimized for optical clarity (mirror polish, Ra 0.4 µm).
- Injection under strict control (minimal contamination, optimized cycle).
- 500 PC parts + 500 PA6 parts, each with their respective finishes.
Result: Parts ready for assembly and clinical testing. Material certificates, documented quality control. Total cost: €18k. With this, you validate with the regulator (CE) without having invested in a production mold. If approval is obtained, the production mold is manufactured knowing exactly which parameters work.
Case 3: Iterative Prototype for Fintech Hardware
Scenario: Housing for a portable payment terminal. Design evolves rapidly based on user feedback (button changes, slot width, height). Material: ABS.
Iteration 1:
- ABS prototype mold. 200 parts. Buttons identified as too tight.
Iteration 2 (2 weeks later):
- Cavity re-machined: button openings enlarged. €800 re-machining, 3 days.
- 300 additional parts. Feedback: improved. But internal height needs +2 mm.
Iteration 3:
- Re-machining: cavity depth adjusted. €600. 3 days.
- Final 500 parts.
Total cycles: 3 prototype mold iterations (conceptually the same mold, iterated) vs 1 single production mold. Total time: 8–10 weeks. With a production mold, it would have taken 14–18 weeks (one production mold at the beginning, but it would have been discarded if the design failed).
Savings: €50k–€70k in discarded tooling costs.
Q: Are prototype mold parts exactly the same as production mold parts?
A: Yes, in material and mechanical properties. The ABS resin we inject in a prototype mold is the same as in a production mold. Nylon, polypropylene, whatever—it’s the same material.
Very small visual/functional differences:
- Surface finish: prototype typically Ra 0.8–1.6 µm; production Ra 0.1–0.4 µm in polished areas. In prototypes, if you look with a magnifying glass, you will see “tool marks.” Functionally, irrelevant.
- Tolerances: prototype ±0.1–0.2 mm; production ±0.05–0.1 mm. For 99% of assemblies, it does not matter.
- Repeatability: 10 prototype parts all come out almost identical. No variation outside specification.
Conclusion: For functional validation, assembly tests, early trials, certifications, the parts are fully representative.
Q: What happens if I change the design after making the prototype mold?
A: That is exactly what we expect. The prototype mold exists for that purpose: to experiment without fear.
Small change (e.g. enlarge a hole by 1 mm, add a 0.5 mm radius):
- Cavity re-machining: 1–2 days of CNC work.
- Cost: €300–€800.
- Re-inject test batch: 2–3 days.
- Total additional time: 4–5 days. Total additional cost: €500–€1,200.
Moderate change (e.g. redesign of cross-section, moving the injection point):
- Deeper re-machining: 3–5 CNC days.
- Cost: €800–€1,500.
- Test re-injection + optimization: 3–5 days.
- Total: 7–10 days, €1,200–€2,000.
Major change (e.g. completely redesigned part, totally different geometry):
- Sometimes it makes sense to build a new prototype mold (instead of modifying the old one).
- Cost: similar to the original prototype mold (€7k–€15k).
- Lead time: 2–3 weeks for a new mold.
- Even so, still faster/cheaper than a production mold.
Key point: The philosophy is “iterate without economic penalty.” That’s why a prototype mold costs 1/10 of a production mold: it is designed to be modified.
Q: Can flash or defects appear in a prototype mold?
A: Yes, it is possible, but rare if the mold is well made.
Flash: small lines of material at the mold parting line. In prototype molds they can appear after thousands of cycles (friction, micro-deformation of aluminum under pressure). Solution:
- Manual: removed with cutter/file (2–3 minutes per part, €0.50–€1 labor).
- Machining: automated deburring (if volume is very high, >10k parts).
- Mold re-machining: if flash is severe, we polish the parting line (€500, 1 day).
Fill defects or bubbles: very rare if the mold is optimized (prior Moldflow simulation, well-designed cooling channels). If they occur, it is usually an injection parameter issue (low temperature, very short cycle), not the mold itself.
Weld lines: in complex geometries where material flows meet, lines may appear. Visually noticeable, functionally OK. If it is a problem, post-injection polishing or injection point adjustment is done (mold re-machining, €500–€800).
Conclusion: serious defects are rare (<5% of molds). But if they occur, they are solved relatively quickly and cheaply thanks to aluminum (easy to re-machine).
Q: What happens when I move from a prototype mold to a production mold? Are injection parameters transferable?
A: Highly transferable, with minor adjustments.
When you move to a production mold (hardened steel, multiple cavities), the data obtained from the prototype is extremely valuable:
- Material temperature: exact. Transfers directly.
- Cycle time: almost exact. The production mold may differ slightly (multi-cavity, different cooling), so cycle time may be reduced by 5–15%. But the starting point is solid.
- Injection pressure: similar, but now multiple cavities must be balanced. The production engineer adjusts it, but the base is validated.
- Known issues: if air traps appeared in a certain area during prototyping, the production engineer already knows how to solve it (better hot runner positioning, additional venting).
Production machine setup time: typically 4–8 hours (vs 2–3 days if starting from scratch without prototype data). Savings: 1–2 days per setup.
Q: What is the real service life of a prototype mold?
A: It depends on material and usage:
- PP/PE (soft): 8,000–10,000 cycles without major issues.
- ABS / unfilled PA: 5,000–7,000 cycles.
- Glass-filled PA (abrasive): 2,000–4,000 cycles (fiber scratches aluminum).
- Flame-retardant materials: 3,000–5,000 cycles (additives can be aggressive).
What happens at cycle 5,001 if the material is PA? The mold does not “explode.” Instead:
- The cavity begins to show micro-wear.
- Fine flash may appear (easy to remove manually).
- Tolerances may open by an additional ±0.05–0.1 mm (less critical if you were already at ±0.15 mm).
- Surface finish slightly degrades (Ra may increase to 1.2–2 µm vs initial 0.8–1.2).
Decision: typically, when you need >5,000–7,000 parts, it is time to evaluate a production mold. Cost-benefit is better. But nothing prevents you from continuing with the prototype for another 2–3k cycles if budget is tight.
Preventive maintenance: weekly cleaning, monthly parting line polishing, clean cooling oil can extend service life by +30–50%.
Q: Do I need a DFM analysis before making a prototype mold?
A: Not mandatory, but strongly recommended (especially if this is your first prototype of the part).
Without DFM: Risks:
- Poorly positioned injection point → incomplete filling, re-machining required.
- Insufficient draft angles → part sticks in mold, high ejection forces, mold damage risk.
- Very thin walls in certain areas → short shots (incomplete fill).
- Visible weld lines in critical areas → unacceptable for customer.
With DFM (includes Moldflow simulation):
- Material flow is validated before machining the mold.
- Risk points are identified.
- Minimal design adjustments are recommended (no functional changes, only manufacturability).
- Injection point is optimized.
- Result: the mold works right the first time, without correction cycles.
DFM cost: usually €500–€1,000 (deductible if you proceed). ROI: avoids €2k–€5k in unnecessary re-machining.
Q: Can I request a prototype mold for “two different parts”? (e.g. red + blue, or small + large size)
A: No, each prototype mold is a single cavity. You would need two molds (one per part).
Exceptions:
- Multi-cavity prototype mold: in special cases, 2 cavities of the same part (if geometry allows). But typically we do only 1 cavity for speed.
- Mold with interchangeable inserts: in some cases, we design a mold with modular inserts (only the internal cavity changes, base plate remains the same). More complex, cost +20–30%.
Recommendation: if you need two different parts in prototype, build two separate prototype molds (€8k + €8k). More expensive than one mold, but still far from the price of a multi-cavity production mold.
Q: What happens to the prototype mold once the parts are finished? Can it be reused or stored?
A: Yes, it can be stored, but there are considerations:
Option 1: Active storage
- We store the mold in our facility under controlled conditions (humidity, temperature).
- If you need more parts in 6–12 months: available, we inject. Storage cost: ~€100/month.
- Fast reactivation: 3–5 days for setup and first parts.
Option 2: Customer storage
- You take the mold to your facility. Customer responsibility.
- Ownership: the mold is yours; you paid for it. You can inject it on your machine (if you have one).
- Risk: mold without maintenance may degrade (corrosion, rust in water channels, aluminum deformation).
Option 3: Dismantling / recycling
- If you will definitely not use it again, we recycle components (aluminum to press, components stripped).
- We recover ~30–40% of material value (not much, but something).
- Dismantling cost: ~€200–€300.
Recommendation:
- If future volume is likely (revisions, additional batches), we store it (€100/month, safe).
- If disposable, we recycle it (€300 dismantling charge).
- Typically, the customer decides after seeing success; many choose to keep it stored “just in case.”
Q: Difference between “soft” and “hard” prototype molds?
A: Non-standard terminology, but here is the clarification:
“Soft tooling”: what we do. Aluminum, medium service life, low cost. ProtoSpain prototype mold = soft tooling.
“Hard tooling”: hardened steel mold, production, long service life. Expensive, slow.
“Semi-hard tooling”: sometimes used term. Non-hardened steel or reinforced aluminum. Service life 20k–50k cycles. Intermediate cost. Rarely offers better ROI than prototype (aluminum) + production (steel), so we do not offer it.
At ProtoSpain, each prototype mold batch includes:
Standard Documentation
- Mold material certificate: specification of the aluminum used (alloy, hardness, origin).
- Machining report: CNC machine used, tools, achieved tolerances.
- T0/T1 injection report: parameters used (temperature, pressure, cycle time), process observations.
- Dimensional measurement (sampling): 10 parts from the batch verified with CMM, critical dimensions, OK/NOT OK result.
- Process photos: optional, but requested for records.
Warranty
- Prototype mold: 90-day functional warranty from delivery. If a manufacturing defect occurs (severe flash, poor filling due to our error), we repair/re-machine at no cost.
- Injected parts: 30-day material warranty. If there is a material defect (porosity, contamination), we re-inject the batch.
ProtoSpain Differentiation: Why Choose Us for Prototype Molds
Local Speed
- 24h response: quotation after receiving CAD.
- Manufacturing in 2–3 weeks: vs competitors who sometimes take 4–6 weeks.
- Fast iterations: if changes are needed, we re-machine in days, not weeks.
- No international shipping surprises: production in Spain, deliveries in 2–3 days.
Accessible Technical Team
- Engineers available: DFM consultations, mold optimization, advisory at no cost (part of the service).
- Phone/WhatsApp: not email only. Urgent issues are resolved via call.
- Transparency: process photos, injection videos if requested. You see exactly what is happening.
Unmatched Flexibility
- Micro-adjusted quotations: if you have a spending limit, we design a mold that respects it (we optimize later).
- Cost-effective re-machining: our CNC is in-house, not outsourced. Modifications are profitable for us and affordable for you.
- Multiple iterations: we expect you to change your mind. We are iteration partners, not transactional suppliers.
Guaranteed Transfer to Production
- Documented injection data: we deliver exactly which parameters work, so the production mold starts directly.
- Production advisory: when you reach commercial injection, we help you select a production supplier and share lessons learned.
- Continuity: many ProtoSpain clients who scaled to production returned to us for consulting (improvements, new projects).
- Upload your CAD: ProtoSpain online portal, or send it by email.
- Describe the project: estimated volume, material (if you don’t know, we suggest one).
- Quotation within 24h: includes mold + injection + finishes.
- Approval: you confirm the quotation, we schedule the timeline.
- DFM analysis (optional): if requested, we perform Moldflow simulation (2–3 days).
- Mold manufacturing: 2–3 weeks CNC + assembly + injection setup.
- Trial injection and production: 1–2 weeks for the complete batch.
Delivery: boxes with parts + quality documentation.
The prototype mold represents the ProtoSpain philosophy: speed, flexibility, quality, without sacrificing economics. It is the tool that allows you to experiment, learn, and iterate without fear of the budget.
It is not a “second-tier mold.” It is a strategic choice: investing conservatively during the validation phase so that when you reach production, you have solid data and the final mold becomes a profitable safeguard, not a blind bet.
Does your next product deserve less? Let’s get straight to the point: contact us, send your CAD, and within 24–48 hours you will know the cost and lead time. No surprises. No detours.
ProtoSpain: from idea to injected prototype, in weeks. From validation to production, without uncertainty.