Frequently asked questions

A prototype mould is an injection tooling designed to produce injection-moulded plastic parts in small batches, using materials and processes equivalent to production. In Pilot2Plant, the prototype mould is based on an existing mould base with a machined insert fitted to the part geometry. This significantly reduces cost and lead time compared to a full production mould.

Traditional prototyping (3D printing, CNC machining, RIM) mainly validates the geometry of the part. Pilot2Plant goes further: it uses the actual final plastic material in a real injection moulding process, allowing analysis of process behaviour (shrinkage, warpage, fill) not just shape. This distinction is critical for making technical decisions before investing in a production mould.

While rapid prototyping (3D/CNC) only validates shape, Pilot2Plant acts as an industrial insurance policy. We manufacture only the custom insert for our standard mould bases, letting you inject with the real production material and capture critical parameters — actual shrinkage, thermal cycles — before making a major investment in the final production mould.

An insert is a machined piece with the part geometry that fits into the existing mould base. The insert defines the injection cavity and can be manufactured in high-hardness aluminium or mild steel, depending on the part requirements. Being independent from the mould base, it can be modified or replaced without redoing the entire tooling.

Capacity varies mainly according to the insert material and the type of resin injected:

• Standard aluminium: between 2,000 and 10,000 shots.
• High-strength aluminium (7075): between 5,000 and 50,000 cycles, depending on complexity and maintenance.
• Abrasive glass-fibre-filled materials: between 1,500 and 3,000 shots in aluminium inserts.
• Unhardened steel: up to 50,000–100,000 units, with greater dimensional stability.

Pilot2Plant is compatible with over 130 thermoplastics and elastomers, including technical-grade medical and automotive materials: PP, PE-HD, ABS, PS, PC, PMMA, POM, PA6, PA66, PC/ABS and their glass-fibre reinforced variants (PA6 GF30, PBT GF30, PPS GF40, PEEK GF30, PA66 GF15/30/50, PA6 15FV/30FV, POM FV). If your material is not on the list, contact us.

Yes. One of Pilot2Plant's key advantages over other prototyping solutions is precisely the ability to use the final plastic material. This provides real shrinkage, warpage and fill behaviour data with the same material that will be used in production.

The plastic material determines parameters such as expected shrinkage, process temperature and finishing requirements. These are taken into account in the insert design and in the selection of insert material (high-hardness aluminium or steel). High-temperature materials such as PEEK or PPS may require steel inserts.

We work to the NFT 58000 standard, offering a Normal Class of ±0.08 mm. For high-precision technical projects, we can adjust the process to achieve the Reduced Class of ±0.04 mm and even tighter values.

Available finishes in Pilot2Plant: No aesthetic requirement (standard machining technical finish), VDI technical texture (applied to the insert), industrial polish and mirror polish with production-equivalent finish. The finish is applied directly to the insert and influences the demoulding process and required draft angles.

Yes. During the technical brief phase, the part's critical characteristics (CTQ) can be defined. The delivery report can include specific measurements of these characteristics, with the values obtained against the stated specification.

The Pilot2Plant process follows 5 stages: 1) Technical brief: part definition, material, objective and minimum batch; 2) Selection of a compatible mould base for the geometry; 3) Insert design: DFM, feed and ejection system; 4) Machining and assembly of the insert in the mould base; 5) Injection of the minimum batch, inspection and delivery of parts and documentation.

Lead time depends on the complexity of the part and availability of a compatible mould base. Generally, from technical brief approval to part delivery, the indicative lead time is 2 to 4 weeks. For the lead time of a specific project, contact our technical team.

To assess feasibility and generate a technical offer, we need: a 3D file of the part (STEP, STP, IGES or STL) and/or a 2D drawing with dimensions (PDF or DWG). If you do not yet have final files, send us what you have and our technical team will guide you.

The cost of a Pilot2Plant project mainly includes: the design and machining cost of the insert, the cost of the injection process for the minimum batch, and the material cost. Variables such as part size, geometric complexity, material and required surface finish directly affect the final quote.

Yes, in many cases. If the design modification is localised, the insert can be modified by additional machining, sub-inserts or welding, generating an iteration cost lower than manufacturing a completely new insert. This depends on the extent of the change and the condition of the insert after the first injection run.