Tooling work sits on the OEM/ODM line, separate from the light-customization runs that use an existing mould. A new mould has a fixed sequence, and the 30 days are spent in a predictable order.

The sequence

  • Days 1–3 — DFM and mould layout. Parting line, cavity count, gate or compression layout, shrinkage allowance against the compound chosen. This is where the geometry argument happens, while it is still free.
  • Days 4–12 — mould design and machining. Steel ordered, plates machined, cavities roughed. A change to the drawing after day 12 usually restarts this block, which is why undercuts and cosmetic faces are settled in the first three days.
  • Days 13–18 — finishing. EDM, polishing of the surfaces that show, venting. Venting is unglamorous and decides whether the first trial produces parts or burn marks.
  • Days 19–23 — trial and adjustment. First shots measured, flash assessed, adjustments made to steel rather than to the process where possible.
  • Days 24–27 — sample run. A small batch produced on the adjusted tool, with the critical features measured against the drawing.
  • Days 28–30 — report and approval. First-article report issued, deviations stated plainly, production released only after your sign-off.

Where the week disappears

In practice, most late programmes are not late in the tool shop. They lose time in four places:

  • Drawing revision after day 12. A cosmetic change, a moved parting line or a new wall thickness resets machining. On a 30-day promise that is the single most expensive kind of email.
  • Undisclosed undercut. Found at trial, it becomes a tool modification rather than a design decision.
  • Material substitution mid-project. Shrinkage changes, so the cavity allowance changes with it.
  • Packaging artwork. The mould is done, but the carton is not approved, so the run waits.

None of these are hidden risks. Each one is visible in the first three days if the file is complete, which is what the 24-hour fit review is for.

What we need on day one

2D drawing with tolerance class, 3D model in STEP or IGES, the application and the temperature the part sees, first-order and annual volume, and the declarations the part has to carry. Packaging artwork can follow later — but not after day 25.

After approval

Once the first article is signed off, production is MadeToOrder and ships in 10 working days. There are no stock lots to draw from: the run is scheduled against the approval date and the purchase order, not against inventory.

Start a tooling programme — or check the process matrix first.