The 5 Most Common Causes of Mould Tooling Delays – and How to Prevent Them

Posted on: 19/05/2025

Category: News, Industry

When it comes to plastic injection moulding, tooling is the critical foundation on which every successful project is built. However, mould tooling delays can quickly derail even the best-laid plans, leading to increased costs, missed deadlines and frustrated project teams.

In this article, we explore the five most common causes of tooling delays and how they can be avoided with the right expertise.

1. Incomplete or Unclear Product Designs

One of the most common reasons for tooling delays is receiving incomplete or poorly defined product designs. Without clear, fully developed CAD models and specifications, toolmakers are forced to make assumptions or wait for clarification, both of which waste valuable time.

How to prevent it: Consult an experienced injection moulder early in the tooling process to produce a production-ready CAD model before engaging a toolmaker.

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2. Last-Minute Design Changes

Design changes made after tooling manufacture has begun can significantly disrupt schedules. Even minor adjustments often require reworking of the tool, revalidation and additional lead time.

How to prevent it: Finalise designs before commissioning tooling wherever possible. If changes are necessary, working with a responsive partner who understands the implications and can advise on the best way to incorporate them is key.

3. Misaligned Expectations on Lead Times

Tooling, especially for complex components, is a time-consuming process. Unrealistic expectations about how quickly a tool can be designed, manufactured, trialled and adjusted often lead to perceived delays.

How to prevent it: Work with a supplier who provides honest, realistic lead time estimates based on your part complexity and production volumes. At Chess Plastics, we can source new tools either in the Far East for more budget-sensitive projects, or closer to home for those with tighter timescales.

4. Selecting the Wrong Tool Materials

Choosing inappropriate materials for tooling can cause quality issues, tool failure and rework, all of which add to project timescales.

How to prevent it: Carefully consider factors such as the expected production volume, the type of plastic being moulded, the complexity of the part, and the tolerances required. Different materials offer varying levels of wear resistance, thermal stability and cost-effectiveness. If unsure, seek expert advice to ensure the chosen tool material aligns with the demands of your project.

5. Lack of Tool Maintenance and Support

Even the best-designed tools can suffer unexpected setbacks without proper maintenance. If a tool breaks down during early trials or production runs, fixing it externally can cause long disruptions

How to prevent it: Choose a partner with in-house toolroom capabilities. At Chess Plastics, we have a dedicated toolroom for tool maintenance, servicing and repairs, helping to minimise downtime and keep projects moving smoothly.

Supporting Your Tooling Journey

Tooling delays are not inevitable. With the right preparation, communication, and expertise, they can often be avoided entirely.

At Chess Plastics, we pride ourselves on supporting customers through every stage of the injection moulding journey – not just production. Whether you need advice on optimising your part design for tooling, sourcing new tools to suit your budget and lead time, or ongoing tool servicing, we are here to help.

If you would like to discuss your next injection moulding project, please get in touch with our team today.