Design freeze confirmed in writing
The drawing to which the tool is cut is the last version you signed. Any changes go through a formal revision.
OEM programme guide
Moving from prototype tooling to production.
Your product is real. You've made prototypes, maybe pilot runs. The design is stable and the volume forecast is starting to be trustworthy. Now the question is: when do you move to production tooling, and how do you do it without breaking what already works?
The trigger
When prototype tooling starts to cost you more than production tooling would.
Prototype and bridge tooling is cheap to make and expensive to run. Every part off a prototype tool costs more in labour and material than the same part off production tooling. As volume grows, that gap becomes the entire economics of your programme.
The migration trigger is when the cost of tooling investment recovers within a reasonable payback period at your current volume. That's usually somewhere between 5,000 and 20,000 parts per year, depending on the part and the route. Below the threshold, prototype tooling is still right. Above it, production tooling is overdue.
The other trigger is design stability. If the design is still moving, production tooling is a mistake — you'll cut steel and then have to modify or replace it. Waiting until the design is frozen is usually worth a bit of extra time on prototype tooling.
For most OEM programmes we run, the migration happens in year two or three, after the first year has proved the product and the second year has stabilised the volume forecast.
The process
Five stages that keep the migration clean.
Migration is a project, not an order. Planning it properly avoids scrapping prototype stock or interrupting supply.
Confirm design is frozen
Any change after this point costs more than it did in prototype. Freeze the design, sign off the drawing, don't allow changes until after first article approval.
Model production economics
Cavity count, cycle time, tooling investment, per-part cost at your volume. We provide the numbers; you decide whether the payback fits your commercial case.
Cut the tool
Steel machined, cavity finished, tool assembled. Depending on complexity, several weeks. Prototype supply continues in parallel.
First article approval
First parts from the production tool compared to the prototype parts and to the drawing. Any dimensional or cosmetic drift addressed before scaling up.
Migrate supply
Production supply ramps up; prototype supply winds down. Typically overlap of one to three batches to avoid supply gap.
Managing expectations
Three things that will feel different.
Cycle time drops, batch size grows
Production tooling produces parts faster. Minimum sensible batch size goes up because setup and change-over is optimised for longer runs.
Small dimensional drift is normal
Prototype and production tools don't produce identical parts. Minor drift on non-critical dimensions is expected; critical dimensions are held to drawing.
Cosmetic finish often improves
Production tools are polished and finished more carefully than prototype tools. Cosmetic quality on visible faces usually goes up.
Watch-outs
Four mistakes we see often when a customer arrives mid-migration from another supplier.
These aren't rare. If any of them are happening to your programme, escalate before they become expensive.
Cutting the tool before design freeze
Change requests during tool cutting cause rework or scrap. If the design isn't frozen, wait.
Optimistic volume assumption
Cavity count sized for a forecast that never arrives. Tool sits underused; per-part cost never comes down to plan.
Skipping the first article approval
Ramp-up starts before the first production parts are compared to the reference. Any drift compounds through the first several batches.
Prototype supply ended too early
Production tool has teething issues. Prototype supply has already been discontinued. Emergency reorders at emergency prices.
Our approach
Four commitments during a production migration.
Payback modelled honestly
We show you the numbers before you commit. If the payback doesn't fit your commercial case, we say so.
Prototype supply retained through ramp
Parallel supply until the production tool has proved itself over several batches. No forced cutover.
Named engineer through the migration
One engineer owns the migration from planning through first article. You have their direct line for questions.
Keep reading
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At a glance
The ideas in pictures.
Which route suits your quantity
Swipe to see the whole diagram
From drawing to delivered parts
- 01Drawing or sampleYour part and where it is used
- 02Material and routeCompound and process agreed
- 03PrototypeReal parts to test
- 04Sign-offYou approve the samples
- 05Production toolBuilt for your volumes
- 06Batches and checksInspected and delivered
Swipe to see the whole diagram
Get in touch
Tell us the part, the volume, and the timeline.
Rough annual volume, target unit price, and any deadlines. That's enough to work out whether compression, LSR injection or something else is the right tool.
Real people, a real workshop
You deal with the people who make it.
No call centre and no middlemen. When you contact TCI Products, you speak to the team who design, build and check your mould.
- A real Warwickshire workshopUnit 15, Waterloo Park, Bidford-on-Avon, Alcester B50 4JG.
- Real people on the phoneCall the team on 01789 224228, Monday to Friday.
- The same team on every jobDesign, production and aftercare come from the people you see here.
- Part of TCI GroupFive specialist brands, one engineering team. Visit TCI Group.
Thomas LaneManaging Director
George PrestonDesign & Project Manager
Kelly BallingerHead of Partnerships
Jim AndertonProduction Manager
TheodoreEmployee Welfare