Medium Quantity Metal Prototypes
For over 50 years, Regal Metal Products has been designing and building the tools that make high-quality stamped metal parts possible. From dies and jigs to fixtures and progressive tooling, our team knows how to create equipment that works, not just on paper, but in real-world production. Whether you need a prototype tool for testing or full-scale production tooling, we’ve got the experience, software and machinery to get it done right.
Why Tool Design Matters
Good tooling is the result of careful planning, testing and refinement. At Regal, we start by understanding exactly how a part will be used, then design tooling that matches those needs.
This means:
- Testing before committing: We often prototype parts first to catch potential issues early, saving time and money on production tooling.
- Balancing cost and performance: Our engineers focus on making tooling that lasts, without unnecessary expenses.
- Matching production methods: Whether it’s progressive dies, single-hit stamping or specialized fixtures, we design tools that fit the way you manufacture.
What We Build
Our tooling capabilities cover a wide range of needs.
1. Dies for Metal Stamping
- Progressive dies: Ideal for high-volume runs, these tools handle multiple operations in one pass, reducing handling and speeding up production.
- Transfer dies: Used for larger parts or more complex shapes, these dies move the workpiece between stations for additional forming.
- Compound dies: These perform several operations (like cutting and forming) in a single press stroke.
Our stamping tools can handle parts up to 60” x 168” and presses weighing up to 600 tons, making them suitable for everything from small brackets to large truck components.
2. Jigs & Fixtures
Sometimes, the right tool isn’t a die. It’s a jig or fixture that holds parts in place for welding, assembly or machining.
We design these to:
- Keep parts aligned during welding or fastening.
- Speed up repetitive tasks in assembly lines.
- Ensure consistency across multiple production runs.
3. Prototype Tooling
Before investing in full production tooling, many customers test their designs with prototype tooling. We offer:
- Short-run tooling: Lower-cost dies for testing part functionality.
- Temporary fixtures: Quick solutions for early-stage production.
Adaptive tooling: Modifications to existing dies for design changes.
How We Design Tools
Step 1: Digital Design with SolidWorks
We use SolidWorks for 3D modeling, allowing us to simulate how a tool will perform before metal is ever cut. This helps catch potential problems early, such as material flow issues or weak points in the design.
Step 2: Prototyping & Testing
If needed, we’ll run prototype parts to verify the tool design works as intended.
This step is especially useful for:
- Checking material behavior under pressure.
- Confirming fit with other components.
- Adjusting tolerances before finalizing the tool.
Step 3: Building & Validating the Tool
Once the design is locked in, our toolmakers get to work machining, assembling and testing the tool.
We check for:
- Durability: Will it hold up over thousands of cycles?
- Repeatability: Does it produce consistent parts every time?
- Ease of maintenance: Can it be serviced without major downtime?
Step 4: Production Support
Even after a tool is in use, we’re here to help with:
- Sharpening & repairs: Keeping dies in top condition.
- Modifications: Adjusting tools for design updates.
- Troubleshooting: Diagnosing issues like excessive wear or part defects.
Industries We Serve
Our tooling supports parts for:
- Automotive: Brackets, mounts structural components.
- Agriculture: Wear-resistant parts for heavy equipment.
- Appliances: Housings, connectors and functional hardware.
- Heavy Truck: Reinforced stampings for durability.
Why Choose Regal for Tool Design?
50+ years of experience. We’ve been doing this since 1965, so we’ve seen and solved just about every tooling challenge.
- Full in-house capabilities: From design to stamping, welding and assembly, we handle everything under one roof.
- Practical problem-solving: We focus on making tools that work in the real world, not just on paper.
Ready to Get Started?
If you need tooling that performs (whether for prototyping or full production) we’d love to help.
Contact Regal Metal today, and let’s build something great together.