Aluminium mould bases for prototypes and short runs from DMS-Diemould are helping Havant-based rapid tooling specialist Formaplex Machining turn round tooling in three days. According to Formaplex, rapid tooling manufacture is all about spindle time. The time from receipt of IGES file to cutting is paramount.

Formaplex use RTM (Real Time Machining) software with anti-collision detection in combination with its own bespoke process to merge jobs and enable global modelling of an infinite number of components.

CADCAM software reads the incoming CAD model file and machining can commence within seconds if required, enabling tooling to be manufactured in a fraction of conventional lead-times.

To help this happen, Formaplex keeps Rapidbases (aluminium mould bases) from DMS-Diemould in stock at its brand new 1750 sq m headquarters for use on its 15 CNC high speed machining centres - some of which have beds up to 5m with five-axis capability, operating 24/7.

'We currently quote delivery from three days for small mould tools,' declares sales director Andy Bone.

'The Formaplex Process removes a substantial amount of the labour content deployed by conventional toolmaking companies - in 2005 we achieved a turnover in excess of GBP4 million with just 12 direct production personnel.' Formaplex manufactures a range of tooling from small, intricate part geometries to large parts and full suites of tooling for both prototype and low/medium volume production injection moulding requirements.

Mr Bone states that the instant availability of Rapidbases is key to getting jobs started quickly.

'Quickly getting into a position to start cutting is what we are all about as a manufacturer of rapid tooling solutions,' he says.

'Rapidbases cut a significant amount of machining time from our processes, helping us better serve our customers in the automotive, medical, domestic appliance and telecoms sectors.

It helps keep the value chain very short and supports our 'can do' approach.' Formaplex is more a 'creative studio of manufacturing', rather than a toolmaker or precision engineering firm.

In its five year history the company has invested heavily in latest design high technology machines, software, tooling and staff with high levels of ability.

With these elements Formaplex is all set to become one of the most successful and dynamic machine shops in Europe