Increasing Production Capacity
When Lead Shield approached Plyable, they were looking to replace an existing tool used in a lead casting application.
At the same time, they wanted to increase output by moving from a single-cavity tool to a five-cavity design. While the objective was straightforward, achieving it was less so.
Expanding the tool from one cavity to five introduced several manufacturing challenges, particularly regarding the component’s geometry. Features that were manageable in a single cavity became significantly more demanding when replicated five times within the same tool.
A Machining Challenge
One of the biggest challenges centred on a series of parallel-sided features and extremely tight radii within the design.
The geometry required a level of precision that couldn’t be achieved using the machining methods we would normally employ. Simply scaling up the existing approach wasn’t an option.
Like many tooling projects, the challenge wasn’t just about manufacturing a part. It was about finding a manufacturing route capable of delivering the required geometry consistently across all five cavities.
Looking Beyond the Obvious
Rather than compromising the design, we worked with our supplier network to explore alternative approaches.
This is where having access to specialist expertise and trusted manufacturing partners becomes invaluable. By drawing on that wider network, we identified a solution that met the required features while maintaining the quality the customer expected.
It wasn’t the most obvious route, but it was the right one.
Putting the Tool to the Test
With the manufacturing approach established, production of the tool could move forward.
The finished five-cavity tool was delivered and tested, producing high-quality castings from the outset. The results validated the approach and provided Lead Shield with a tooling solution capable of supporting increased production requirements.
For the customer, the project delivered more than a replacement tool. It delivered a route to higher productivity without compromising part quality.
Engineering Solutions, Not Just Tools
Projects like this are a good reminder that tooling is rarely just about machining metal.
Every application brings its own challenges, whether that’s geometry, materials, production volumes, lead times, or manufacturing constraints. The solution often comes from understanding the problem in detail and being willing to explore different routes to achieve the desired outcome.
For Plyable, that’s where the combination of engineering knowledge, manufacturing experience, and a strong supplier network can make the difference.
In this case, what began as a replacement tool became an interesting engineering challenge. The result was a robust five-cavity solution that met the customer’s requirements and helped support future production growth.
