Cross-Functional Planning
Effective tablet design requires collaboration across departments. While marketing may envision unique tablet shapes, involving marketing, R&D, production, engineering, and a reputable tooling manufacturer at the outset ensures every concept is manufacturable and cost-effective. Early cross-functional engagement prevents delays and costly last-minute changes in production.
Key Considerations Before Tooling Selection
Asking the right questions early helps identify technical challenges before scaling up. Consider:
- What tooling configuration does the tablet shape need?
- Will higher compression forces be necessary for the cup design?
- Is the formulation likely to cause sticking or picking?
- Could heat generated during compression affect the product?
- Are the tablet ingredients abrasive or corrosive?
Addressing these questions guides tooling partners to recommend the best design elements, steels, and coatings, optimizing efficiency and minimizing risk.
Importance of Steel Selection
The choice of tool steel is dictated by product behavior and manufacturing demands:
- General Formulations: S1 or S7 punches and D3 dies offer reliable performance for most tablet types.
- Abrasive Materials: A2, D2, or DC53 steels provide enhanced durability for tough formulations.
- Corrosive Actives: Stainless tool steels such as 440C or M340 resist chemical breakdown and extend tooling life.
- Extreme Wear: Carbide inserts for punch tips or dies are ideal, but require reinforced cup designs to prevent breakage during high-pressure compression.
