Duel Systems

Duel has structured and developed its engineering and tooling teams for high quality and rapid product/tooling development. We are the most flexible and responsive company in the industry. Duel's in-house product engineers will design a custom package and its tooling for your application utilizing the latest CAD software, mold flow analysis software, 3D solid modeling software, and/or Stereolithography (SLA).

As part of our customer service, we will work with you on your design from concept to production and continuing through the life of the product. Our tooling project managers will use their expertise to review your design for aesthetics, durability, cost, and manufacturability. They will work closely with you to offer resolution on design issues that will impact effective product design.

If you do not have a design for your product, our engineering design team will create a custom design for you. We can work from a verbal concept, a “back of napkin” design, or a fully fleshed out 3D model. Our in-house design center is equipped with state-of-the-art 2D & 3D CAD software allowing the engineering and tooling teams to operate at maximum effectiveness. We manage the process from start to finish providing you with a seamless transition from part design, to tooling, to pilot production, and through full production.

We provide on-going support for both new and existing package designs. In an effort to keep the engineering and tooling teams familiar with our customers, each member of the team has specific responsibilities for engineering support on each project. Our customers have immediate access to our engineering and tooling resources for product inquiries. Optimization of materials and reduction of unnecessary operations are often enough to gain a competitive edge. Let us help you find these opportunities.

We partner with our family of companies to provide services and products in the USA, Europe, and Asia. Once your tooling is designed, your product may be fabricated in the USA or overseas for mass production. We use our expertise to design, tool, and deliver the best possible product with usable parts right from the first production run.

We’ve created sophisticated modular dies and molds that allow us to provide you with the best solutions to your design needs, while minimizing your tooling cost and lead times. We specialize in modular tooling that allows multiple parts to be made from one basic tool and a number of inserts.

An engineer project manager will be assigned to your account and will work with you to refine your design to best utilize our modular tooling, while ensuring the best design for your product. Early involvement in your product design can yield both quality improvements and enhance the functionality of your parts. Recommendations will be made to improve manufacturability. This reduces your cost.

• Modular die and mold built to reduce cost
• Production engineering expertise to reduce your engineering burden
• Tooling design with fabrication in the USA and overseas for mass production
• Prototype tooling - the prototyping process is not only a logical place to enhance, modify and test component features but also manufacturing methods
• Soft tooling for small volume with short lead times
• Domestic and off-shore tooling sources
• Project management from design to production for the life of the product
• Rapid problem resolution from design through manufacturing
• When you purchase parts from Duel we will maintain your tooling for the life of your product – if it breaks or needs maintenance, we fix or repair it with no cost to you

Our strength is in designing and building dies for your most demanding applications. We start with a thorough review of your specifications and finish with a production-ready die that is quality capable and easily maintained and modified. All of our dies are built as Class A tools. We will also make recommendations, where applicable, that may increase die life and improve the capability of your tooling. Some of our die options include:

• Progressive multi-station dies
• Progressive dies with complex side action station(s)
• Progressive compound dies
• Simple blanking dies
• Precision thin metal stamping
• Strip or single part stamping
• Production volumes ranging from 1 thousand to 1 million parts a month or more
• Press capacities from 20-110 tons
• Small hand/hydraulic presses for low volume/low cost operations

Duel’s mold tooling team builds all of our molds using Class 101, 102 and 103 tools. We have dedicated mold bases for prototyping, soft tooling and testing applications to reduce cost and lead times. We specialize in precision plastic injection molded parts using filled, modified, standard or special engineering grade resins. We offer injection molding tooling and parts with tight tolerances and unique shapes including:

• Precision mold tooling
• Modular and custom mold tooling
• Strip molding
• Single part to multi-cavity molding tools
• Family tool molds
• Overmolded parts
• Two-shot molding
• Insert molding
• Custom presses for insert molding
• Patented insert molding process
• Hot runner systems
• Familiar with a variety of materials including flame retardant and glass filled materials
• Multiple colors and familiarity with color matching
• Modular injection systems
• Press capacities from 20-120 ton presses
• Horizontal and vertical molding machines

• Prototypes and soft tooling: 2-3 weeks
• First class dies and molds: 4-8 weeks depending on complexity (custom dies and molds require longer lead times and will be quoted upon request)