Rohacell

Precision-Machined Lightweight Tooling for Advanced Composites

Rohacell

Not every tooling application needs Invar or carbon fibre.

For prototype development, short-run production, and weight-critical applications, Rohacell offers something no other tooling substrate can match: exceptional dimensional stability at a fraction of the weight, with machinability that allows us to achieve the same profile tolerances we hold on aluminium.

At RM Design & Engineering, we've machined hundreds of Rohacell tools, from aerospace development moulds to motorsport trim fixtures. We understand how the material behaves under cutter load, how it responds to temperature, and critically, how to design tooling that exploits its properties rather than fighting them.

The result: lightweight, dimensionally stable tooling delivered fast and machined to the same standards as our metallic work.

Why RM Design & Engineering?

Because We Machine It Every Day, Not Once a Quarter

Most machine shops treat Rohacell as an occasional material, something they'll have a go at when asked. Feed rates are guessed, cutter selection is wrong, and the tool comes off the machine with chatter marks and torn surfaces.

We machine Rohacell routinely. We know which cutters work, which speeds deliver clean surfaces, and how to fixture lightweight billets without distortion. That daily familiarity means our customers get tooling that looks and performs like it was machined from solid aluminium, at a fraction of the weight and lead time.

We don't just manufacture Rohacell tooling.
We deliver lightweight manufacturing solutions backed by real machining expertise.