Case Study: BK Tooling achieves 'right-first-time' smart tooling and 5-week mould delivery with Vero Software (VISI)

Vero helps smart tooling production

BK Tooling is a Hertfordshire sub‑contractor that designs and produces prototype and low‑volume plastic injection moulds using a standardized “smart” production method and investment in high‑speed machining. For a rear passenger armrest in a PC/ABS blend they faced complex 3D geometry, tight micron tolerances, thick‑to‑thin sections and the risk of sink marks, gas traps and part failure — all while needing a rapid turnaround.

BK imported the STEP model into VISI Modelling, used VISI Analysis and VISI Flow to create split lines and simulate filling, and revised the tool design (coring problem areas, rib extensions and floating inserts) before generating optimized toolpaths and machining on an XYZ 1060 HS with Meusburger components. The simulation accurately matched actual moulding, the mould was designed, cut and built within five weeks, and the process supported a >99% first‑time strike rate with reliable, optimized production.

BK Tooling

Bob Tunks

Owner