Harvester came to me with the request to create a new product line while implementing a lower tooling cost. Traditionally high quantity production runs of vacuum formed products require cast aluminum molds, which are quite expensive to produce.  It was important to keep the new molds aluminum so the solution was to use aluminum sheets and cut all components out on a CNC water jet machine. Each piece interlocks and requires minimal welding without sacrificing strength or performance. At 1/3rd the cost of cast tooling the new style of tooling was deemed a success and was utilized across the entire product line.