At Rockeypad, we meticulously manage the tooling design and manufacturing process to deliver superior silicone keypads. Our skilled engineering and manufacturing teams employ cutting-edge equipment to produce precise and high-quality molds and tools.
Our robust tooling development system, featuring up to 40 design steps, ensures optimal results and mitigates production costs. We emphasize clear communication and collaboration, engaging with clients to ensure reliable and efficient tooling solutions.
Choose Rockeypad for high-caliber tooling that consistently meets the highest standards. Our advanced technology and dedicated approach are designed to exceed your expectations. Contact us today for expert precision in tooling design and manufacturing.
Common Types of Mold Steels
1. P20 (P20HH): This steel is commonly used in injection molding due to its excellent machinability and wear resistance. It is well-suited for small to medium-scale production and straightforward parts.
2. S136 (S136H): Known for its high hardness and corrosion resistance, S136 is a stainless steel ideal for demanding injection molds, especially those involving high production volumes and intricate designs.
3. NAK80: This high-hardness, heat-treated steel is designed for creating molds with high-gloss or mirror finishes, offering superior surface quality and durability.
4. 718 (718H): A premium choice for medium to large-sized molds, 718 steel is highly resistant to wear and is suitable for high-volume production with complex geometries.
5. 2738 (P20+Ni): Enhanced with nickel, this pre-hardened steel is ideal for large injection molds and high-performance engineering plastics, providing robustness and longevity.
6. 2316: This stainless steel is valued for its exceptional corrosion and wear resistance, making it ideal for producing highly transparent molded parts.
Selecting the appropriate mold steel is critical for achieving optimal performance and durability in various mold designs and applications.
| Hardness | 30-50HRC or as ordered |
| Lead Time | 3- 6 weeks after getting the mould design confirmation |
| Drawing Format | .stp / .step / .igs /.stl /.dwg / .pdf |
| Surface Treatment | Matte, Common polishing, Mirror polishing, Texture, Laser Engraving, Power Coating (Painting), Printing, Segmented colors, Mixedcolors, etc. |
| Mould Material | No. 50 steel, No. 45 steel, P20, 8407, H13, 718H, etc. |
| Mould Life | 100-500K shots |
| Mould Testing | All of the moulds can be well tested before the shipments. Videos for moulds trial running are available. |
| Inspection | 100% inspection by QC, QA before shipping. |
| After Sales Service | Available by our staff with more than 20 years of working experience in this field |
Types of Tooling
1. Prototype Tooling:
Prototype tooling also referred to as soft or rapid tooling, is used to evaluate fit, form, and function before initiating full-scale production. Utilizing materials such as silicone rubber, aluminum alloy, and soft steel, this approach is both cost-effective and adaptable. It offers rapid production, reduced investment costs, and provides accurate components for testing and validation.
2. Production Tooling:
Production tooling is designed for high-volume manufacturing, emphasizing precision and efficiency for sustained success. Although it demands greater resources and investment, the benefits include enhanced durability and consistency across large production runs.
3. In-House Design and Tool Adjustments:
By managing tool adjustments internally, we eliminate the delays associated with external tooling vendors. This approach allows for precise dimensional control and optimized tool geometry, ensuring timely and accurate modifications.
At Rockeypad Innovative, we excel in delivering high-quality, custom production tooling solutions. Our expertise spans from prototyping to full-scale manufacturing, providing cost-effective and efficient tooling that aligns with customer specifications. We prioritize streamlined tooling design to enhance manufacturability while minimizing overall expenses.
Main tooling manufacturing machines
| Machinery | Quantity |
| High speed of 42000 and precision CNC | 2 |
| Other 7 CNC Machines | 7 |
| Makino Sinker EDM | 4 |
| Sodic Wire EDM | 5 |
| High Precision Grinder | 5 |
Surface Treatment Methods
1. Polishing:
This process involves grinding and buffing to achieve a smooth, high-gloss finish. It enhances the visual appeal of the surface while minimizing friction and reducing adhesion issues.
2. Coating:
Surface coatings such as chrome, nickel, or titanium plating are applied to enhance protection and wear resistance. These coatings provide a durable layer that extends the lifespan of the mold.
3. Spray Painting:
This method involves applying specialized coatings that offer protection or modify surface properties. For instance, anti-corrosion and anti-stick coatings are used to enhance the functionality of the mold.
4. Nitriding:
Nitriding involves treating the surface with nitrogen gas to increase its hardness and wear resistance. This process is effective in enhancing the longevity and performance of the mold.
5. EDM (Electrical Discharge Machining):
EDM creates micro-spark holes on the mold surface to improve quality and reduce issues related to adhesion. This technique ensures a refined surface finish.
6. Sandblasting:
Sandblasting uses high-pressure gas mixed with fine sand particles to remove contaminants and improve surface quality. It prepares the mold for further processing or coating.
Each of these surface treatment methods is tailored to meet specific manufacturing requirements and ensure optimal performance and longevity of the mold.
Tooling Development Process
The tooling development process begins once the design is finalized in collaboration with toolmakers. The part moves to the T1 sampling stage, which involves initial tool construction. Typically, building the first tool takes 4-8 weeks, depending on the design specifics. T1 sampling is crucial for validating tooling functionality and producing prototype parts.
Following approval of T1 samples, any necessary adjustments and mold texturing are performed, resulting in T2 samples within 1-2 weeks. These samples are evaluated for texture and appearance before proceeding to the contract manufacturer.
At the manufacturer's facility, T2 samples are used to develop the production process and qualify the parts. Molding studies are conducted to determine optimal conditions and refine the process, ensuring that parts meet specifications. Experimental trials help define the processing parameters and their effects on part quality.
Once process development, qualification, and validation are complete, the tool enters routine production maintenance. This phase includes ongoing monitoring to assess wear and address any issues that could impact part quality or tooling longevity.
Experience Excellence with Rockeypad
At Rockeypad, we leverage decades of expertise in tooling design, specializing in plastic and LSR injection molding, over-molding, silicone compression molding, and extrusion. Adhering to ISO 9001 and IATF 16949 standards, we exceed rigorous customer specifications with unparalleled precision and reliability.
Our commitment to craftsmanship is reflected in our lifetime guarantee on all in-house tooling. Choose Rockeypad for superior quality and enduring excellence. Contact us today to discover how our tooling solutions can elevate your projects.