I have a part that's been in production for a few years. Its made out of a 35% glass filled Zytel. The mold tooling is aluminum. The last shipment of parts we got in were fine and now there is one feature on our part that is out of tolerance (by about 0.003" on a .750" diameter bore) on the parts they are making for us right now. Our supplier says there is material wear on the aluminum tool. Does anybody know if it is pretty common for a tool to just all of a sudden show signs of wear? I was kind of expecting the tool to wear down more gradually than that. Is this typical?
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