Prototype tooling often makes a process look more stable than it really is. In early development, the main goal is to get the part made, prove the concept, and move the project forward. A component only has to perform long enough to confirm that the design works. It does not have to survive months of repeated cycling, constant contact, or the pressure of full production output.That is why scale-up exposes problems that were easy to miss during prototyping. A setup that looked dependable in a short run starts drifting once production speed increases. Wear appears faster than expected. Alignment becomes less reliable. Rework begins showing up in places that once seemed settled.This is where small tooling choices start to matter a great deal. Pins are a good example. They are easy to treat as ...
