Case Study


At RP Technologies, we specialise in the complex.

We enjoy taking on new manufacturing and engineering challenges which might frighten lesser toolmakers.

So when Leoni came to us and asked us to manufacture a single impression aluminium tool with steel inserts, we were more than happy to oblige.

The project required some extensive planning and problem solving in order to get the tooling absolutely right.

Let’s take a closer look at how we responded to this interesting challenge…..

Aluminium Tool Precision Engineered
The Brief

With around 100,000 employees in 28 countries, Leoni is a global supplier of wires, cables, and optical fibres to a variety of industries, including the automotive and electronic sectors. 

One of RP’s longstanding customers, Leoni approached RP and asked us to manufacture a single impression aluminium tool with steel inserts.

The Challenge

Leoni required only a small number of plastic injection moulded parts from the aluminium tool which they asked us to build. 

However, these parts, though low volume, would be highly intricate and complex in their design. 

In terms of toolmaking, this meant that we would need to manufacture an aluminium tool which was extremely high in precision, and which featured some very complex contours and geometries.

To achieve this, the tool would need to undergo extensive spark erosion. Over 30 electrodes were used to create the cavity, also sparking the tool joints together in order to produce shut off features that were perfect. 

The tool needed to be produced to incredibly tight tolerances. Leoni stipulated that no flash would be permitted on the part.

P20 steel inserts were used to increase strength and to add to the longevity of the tool, ensuring that high quality, repeatable plastic components could be reproduced over time.

Injection Mould Tool Complex Design
Precision Engineered Aluminium Tooling
The Results

The aluminium tool was made in a very short period of time.

Our CAD designers were involved in the project from start to finish, overseeing the successful delivery of the tool and the final components with great care and attention.

100 plastic injection moulded components were required by our customer, and we made a tool that was guaranteed for at least ten times that amount. 

The parts produced were made from glass filled nylon and were manufactured to extremely tight tolerances. Our Quality Engineers fully inspected the finished components, subjecting  them to a rigorous process of testing and development before they were signed off for dispatch.

We made these parts to a high level of quality, within the agreed timeframe, and at very competitive cost.

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