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The History Behind Hybrid Tooling
The Hybrid Tooling process is a scientific proprietary process developed by engineers at Forecast3D in 2002, and is the result of years of research and experience with the RTV technology and CNC machining. Acting as a bridge tool, it is the only process available in the country that will achieve a tolerance of .0015" inch per inch after the first inch in all axes from a silicone molded part.

Hybrid Tooling replaces the need for engineers to have to rely on designing for thermo or pressure forming or investing in expensive and unwarranted injection molding for low-volume product launches. It is perfect for introductory medical devices or industrial programs, and serves as an ideal process for mid to large skins and housings. Further, it allows engineers to design for injection molding.

Silicone parts and keypads are also well suited to the hybrid process, especially when very thin webbing under the buttons is required, or when you just need beautiful precision castings with nice crisp edges. Like ProCAST, the Hybrid process will also produce parts with color and texture already in the part. Painted parts scratch easily and many casting houses paint parts just to cover flaws and filled voids in the casting. 

When using a typical silicone tool process involving SLA, Objet or CNC patterns, the parts endure demolding stress that causes them to eventually lose their shape, resulting in a more loosely toleranced pattern. On occasion, the pattern will even break while being demolded. Even a CNC model from ABS will be stressed when being pulled from a poured mold sometimes resulting in damage. 

The Hybrid process allows the same precision to be repeated time and time again.  Your parts will look and function perfectly, fit well with your mating parts, and be flat, straight, and geometrically correct. 

Production parts produced from the Hybrid process go through rigorous QC inspections to assure they mate well to the assembly. We monitor these jobs with special attention to ensure they help our customers make it through testing.