Services: Tooling

At Kea-Flex, we carefully select our tooling materials based on the specific needs of each rubber moulding project to ensure the highest quality and efficiency. Steel and mild steel are some of the most popular materials used due to their strength and precision, perfect for producing durable moulds for high-volume production. Aluminium is also a reliable choice, with its quick machining and cost-effectiveness, is ideal for our prototyping and low-volume manufacturing, allowing us to develop prototypes swiftly. This strategic choice of materials enables us to meet diverse project requirements, maintaining a balance between quality, cost, and turnaround time, tailored to the unique specifications of each client’s project. For detailed insights into our processes or material preferences, we encourage you to speak to us directly.

Chrome plating, a process that involves the application of a thin layer of chromium onto a metal object, is widely valued for its extensive range of benefits.  A notable advantage is its substantial resistance to abrasion, corrosion, and oxidation, which can extend the life of a mould up to three times longer, significantly impacting the longevity and durability of tooling components. This resistance is crucial for maintaining operational integrity and productivity in moulding operations. Furthermore, chrome plating simplifies the demoulding process, leading to more efficient production cycles and minimized downtime, while its ease of cleaning and maintenance helps keep moulds in optimal condition longer, thereby reducing operational costs. The hard chrome plating process itself is known for its durability and longevity, improving the wear life of the base material significantly, which is particularly beneficial in the demanding environments of rubber moulding. It also allows for the plating of a wide range of metals and complex geometries, ensuring strong adherence and minimal risk of delamination or flaking, making hard chrome plating a cost-effective solution for enhancing the wear resistance, hardness, and corrosion response of industrial parts.

At Keaflex, we take pride in our ability to design and engineer tools in-house, offering our clients bespoke solutions tailored to their specific needs. Our team of experts utilises the latest technologies and methodologies to ensure the highest quality and efficiency in tool design and manufacturing. However, we also understand the value of collaboration and flexibility in meeting our clients’ diverse requirements. To this end, we sometimes partner with alternative toolmakers, leveraging external expertise and resources to complement our capabilities. This hybrid approach allows us to maintain high standards of quality and innovation while ensuring we can meet the wide-ranging demands of our projects and clients efficiently. For more information on our tool design and engineering services, including our partnerships with other toolmakers, please contact us directly.

The decision between a single mould and a multi-cavity mould is tailored to each project’s volume, complexity, and budget. Single moulds are ideal for projects that require low-volume production or highly complex parts, offering the advantage of dedicated attention to detail and quality for each piece. However, a disadvantage is the higher cost per part, making it less economical for larger runs. Multi-cavity moulds, on the other hand, excel in high-volume production, significantly reducing per-part costs and improving efficiency. The downside is they may not be as flexible in accommodating complex part designs or changes in the production run. We consult with clients to determine the best approach, leveraging our expertise in tool design and moulding to deliver optimal solutions. Whether prioritising precision or efficiency, Keaflex is dedicated to meeting project demands with custom solutions. For more on our moulding options, please contact us directly.

Tool life expectancy is dependent on the tooling material, part complexity, usage conditions, and maintenance. Hardened steel tools, ideal for high-volume production, can last for hundreds of thousands to over a million cycles with proper care, whereas aluminium tools, better for prototyping or low-volume runs, offer a quicker but shorter-lived option. The part’s complexity and the tool’s operating conditions also significantly impact lifespan. Regular maintenance, including inspections and repairs, is key to maximizing tool longevity. We tailor our tooling recommendations to each project’s specific needs, ensuring an optimal balance between durability and cost. For insights into extending the life of your tools or for specific enquiries, please contact us directly.