85%

Faster than traditional tooling

4 Days

Typical delivery

60%

Cost Reduction

204°C

Max temperature

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Proven Results

Complex geometries impossible with machining

Complex geometries impossible with machining

Direct CAD-to-production workflow

Direct CAD-to-production workflow

204°C

Temperature resistance up to 400°F/204°C

±0.1mm dimensional tolerance

±0.1mm dimensional tolerance

Our Advanced Mould Creation Process

Four-stage proven methodology delivering production-ready tooling

Process Grid
1

Design & Engineering Optimisation

Complete CAD integration and thermal analysis for optimal performance

  • Direct import from SolidWorks, NX, CATIA
  • FEA thermal simulation for shrinkage prediction
  • DfAM optimisation for LFAM benefits
  • Complete thermal analysis workflow
2

Intelligent Material Selection

Expert selection from comprehensive Dahltram material range

  • Process temperature matching (65°C to 204°C)
  • Mechanical load analysis
  • Production volume optimisation
  • Surface quality requirements
3

Hybrid Manufacturing Excellence

Zeus/Medusa production with integrated CNC finishing

  • Large-format printing with real-time monitoring
  • Optimised bead placement for strength
  • Continuous thermal and dimensional tracking
  • Integrated CNC milling to ±0.1mm tolerances
4

Professional Surface Preparation

Complete finishing system for production-ready tools

  • ToolPrep Solo primer application
  • Print-Seal treatment for release properties
  • Tool Valve installation for vacuum bagging
  • Dimensional inspection and validation
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How We've Solved Traditional LFAM Tooling Challenges

Addressing the five critical limitations that have held back 3D printed tooling adoption

Material Limitations

Problem: Limited temperature and strength options

Solution: Dahltram range from 65°C to 204°C

Benefit: Aerospace-grade materials including PEI and PESU for extreme conditions

Surface Finish Quality

Problem: Poor finish requiring heavy post-processing

Solution: Hybrid manufacturing with CNC finishing

Benefit: Ra 6.3μm finish using ToolPrep Solo for production-ready surfaces

Dimensional Accuracy

Problem: Materials fail at high process temperatures

Solution: Proven materials tested to service conditions

Benefit: Dahltram I-350CF and U-350CF deliver 204°C performance for demanding applications

Thermal Management

Problem: Tools wear out too quickly

Solution: High-strength materials with professional finishing

Benefit: Carbon fibre reinforcement and surface treatment extend tool life to production volumes

Proven Applications & Success Stories

Real-world results across multiple industries and applications

Compression Moulds

Compression Moulds

Automotive body panels and bumpers

Aerospace wing sections and fairings

Consumer product housings

Large-format packaging tools

Case Study: Malcom Nicholls car bonnet mould - 4 days vs 4 weeks traditional, 60% cost savings

Transfer & Injection Moulds

Transfer & Injection Moulds

Rubber component production

Medical device housings

Multi-cavity production tooling

Precision dashboard components

Material Recommendation: Dahltram C-250CF optimal for thermal cycling performance

Composite Layup Tooling

Composite Layup Tooling

Aerospace structural components

Automotive carbon fibre panels

Marine hull sections

High-temperature autoclave tools

High Temp Option: Dahltram I-350CF for autoclave applications up to 204°C

Vacuum Forming Tools

Vacuum Forming Tools

Large-format thermoforming

Automotive interior trim

Architectural facade panels

Custom packaging solutions

Integration: Tool Valve 125/150 for professional vacuum connections up to 260°C

Ready to Transform Your Tooling Timeline?

Join manufacturers already saving 85% on production time with our proven LFAM mould services

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