What lead times are typical for tool development and pilot production?
What Lead Times Are Typical for Tool Development and Pilot Production?
Standard Lead Time for Tooling Development
The development of die casting tooling typically requires 20 to 35 working days, depending on part geometry, alloy selection, and mold complexity. At Neway, accelerated soft tooling can be produced faster using aluminum or hybrid inserts while maintaining dimensional reliability.
For common aluminum alloys like A380 or A360, standard tool development includes:
CAD modeling and mold flow simulation: 2–4 days
Material preparation and block machining: 3–5 days
Tool cavity CNC machining and EDM: 7–10 days
Mold assembly and bench fitting: 4–6 days
Initial T1 sampling and correction loop: 3–5 days
Neway provides all tooling in-house using precision tool and die making techniques and durable materials like H13 steel and P20 steel.
Typical Pilot Production Timeline
Once the tool is approved through a T1 sample inspection, pilot production usually starts within 5 to 7 working days. This phase includes small-batch casting for validation under near-production conditions. Lead times for pilot production are typically 7 to 10 working days.
Pilot runs typically involve:
Quantities of 50 to 500 parts
Casting under production-intent pressure and temperature
Optional post-treatments like anodizing, powder coating, or CNC machining
Factors That May Affect Lead Times
Mold complexity (e.g., sliders, undercuts)
Multi-cavity tooling configuration
Required surface finishing or tight tolerance machining
Volume and inspection scope for pilot batch
Certification or testing requirements
Neway applies efficient design engineering principles and simulation tools to eliminate delays and ensure tool readiness on schedule.
End-to-End Support from Neway
Neway supports customers across the full product development cycle with:
Fast, in-house tool and die creation
High-precision metal casting for validation
Integrated finishing via post-process, assembling, and testing
