RSP Tooling is a new process that produces production quality forging dies in prototype timing. The process is an indirect spray form process that was invented by Dr. McHugh of the Idaho National Engineering and Environmental Laboratory(INEEL). The process has now been commercialized by RSP Tooling, LLC and tools have been manufactured and put into production in forging operations since January of 2004. Several case studies will be presented that demonstrate the process is faster and less expensive than normal production tooling. The case studies also confirm that the tooling is equal to or better than standard tooling produced from the same metal.

There are obviously several benefits to both the tool shop and the forger when the tools are less expensive and faster. One not so obvious benefit is the ability to use RSP Tooling to open up new markets. It is fairly well known that customers are afraid to try a forging because there is no inexpensive way to make a prototype forging. All the high costs of production forging dies need to be spent even if there is only one part to be made. Since RSP Tooling can produce a tool in a time and cost that is comparable to other processes prototype methods that argument can be discounted. The off shoot benefit that comes from this is that when the customer approves the prototype manufacturing can begin immediately. This is because your prototype die is also your production die. This proposal will be confirmed by presenting typical examples of production dies including cost, time, and life comparisons.