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Probably one of the most common reasons for using plastics in tools is to
reduce the cost of the tool. The following recommendations can frequently help
reduce costs to a minimum:
1. Simplify tool design. A tool design consisting of word descriptions and
sketches in conjunction with the part print eliminates the need for a complicated,
completely dimensioned drawing, and may be the first step toward cost
reduction.
For example, drill jigs made of glass-reinforced plastics laminates and used to
drill holes in shaped sheet metal parts are frequently made from a sample part
which has the holes drilled in their correct location. Directions for such a tool
might consist of a free-hand sketch, or markings
on the part itself with a written description specifying laminate thickness and the
size and type of drill bushings required.
4. Use flat run-outs. Flat run-outs are easiest to build, and should be
used wherever possible.
9. Pot large flat tool areas. Slow expensive machining of large areas can
be eliminated by potting surfaces from a surface plate to pads, ribs, or
whole continuous surfaces.