Rethinking short-run tooling
Advanced Clay Tooling helps architectural brick and ceramics manufacturers deliver short-run production faster and more cost-effectively. We combine production-ready tooling with advanced digital design and development workflows to reduce risk, shorten lead times and support the testing and launch of new product ranges.
About Us
Precision Tooling, Digital Innovation
Advanced Clay Tooling provides production-ready tooling and digital development services for the brick and ceramic industry, with a focus on short-run and specialist production.
Our approach combines advanced digital design, optimisation and additive manufacturing to overcome the cost, time and rigidity of conventional tooling.
Built on years of collaborative research and industry experience, we work closely with manufacturers to deliver tooling that:
- Performs reliably in production
- Offers faster turnaround
- Makes short-run manufacture commercially viable
What We Offer
Our Services
Production-Ready Tooling for Short-Run Manufacture
We design and manufacture production-ready tooling specifically suited to short-run architectural brick and ceramic production. Our tools are engineered for reliability, repeatability and rapid deployment within existing manufacturing processes.
Extrusion Dies
Digitally designed extrusion tooling optimised for material flow, perfect for short runs and complex profiles.
Press Moulds
Precision press moulds that enable flexible production of specialist and low-volume products without the cost and lead time of conventional tooling.
Texturing Tools
Custom texturing tools that allow surface variation and design differentiation within short-run production.
Integrated Digital & Development Services
Alongside physical tooling, we provide a suite of digital and development services that reduce risk, improve performance and accelerate time to production.
CAD, Parametric Design & Generative AI
Advanced digital design workflows that enable rapid iteration, variation and design exploration within defined manufacturing constraints.
3D Scanning, Reverse Engineering & FEA Optimisation
Accurate capture of existing products and tooling, reverse engineering for replacement or heritage products and FEA optimisation for weight reduction.
Rendering, VR & Digital Visualisation
High-quality visualisation and immersive tools for internal review, client demonstrations or website / catalogue integration.
Material Flow & Tool Optimisation
Simulation-led optimisation of material behaviour and tool geometry to improve forming quality, reduce defects and extend tool life.
3D Printing with Heat- and Wear-Resistant Composite Polymers
Rapid additive manufacturing of tooling and components using advanced composite polymers suited to production environments.
Testing & Sample Production
In-house testing and sample production to validate designs, assess performance and de-risk short-run manufacturing.
R&D Support for New Products and Processes
Targeted research and development support to explore new product concepts and manufacturing methods, providing a low-risk pathway from experimentation to production-ready tooling.
Traditional Tooling Challenges
Why traditional approaches fall short
Typical limitations include:
- Long lead times
- High upfront investment
- Limited adaptability for change
- Capital tied up in rarely used tools
Faster, flexible, digital-first tooling
Our Approach
Our digital-first workflow replaces slow, rigid tooling routes with a fully integrated process designed for short-run production.
By combining 3D scanning, CAD, in-house optimisation software and additive manufacturing, we deliver production-ready tooling in a fraction of the time and cost of conventional methods. This approach enables faster iteration, earlier validation and greater confidence in short-run manufacture without committing to over-engineered tooling designed for mass production.
Practical tooling solutions, delivered with speed and clarity
What We Offer
Our offering focuses on:
- Digitally driven tooling design that enables precision, repeatability and flexibility.
- Rapid prototyping and production that reduces lead times from months to days.
- Integrated consultancy and review to refine designs and de-risk manufacture.
- Competitive pricing that makes short-run production commercially viable.
Once a design direction is agreed, we provide clear scope, fast turnaround and transparent pricing allowing manufacturers to move confidently from development into production.
How to Place an Order
Get started with short-run tooling
Share your requirements, production goals and technical details.
Provide a 3D file, drawing, texture image, concept or physical sample.
Receive a clear quote or project plan, typically within 1-2 working days
Indicative pricing from £1000 per tool (depending on project requirements).
Tooling is digitally developed to your specifications (scanning, CAD, optimisation etc)
Renders and 3D models can be provided at this stage for validation.
Optional production and delivery of physical samples.
Additive manufacturing of tooling in composite polymer.
Tooling delivered ready for production, often within 10 working days of project inception
Digital files shared (scans, 3D models, height map textures, etc).
Additional copies of tools can be ordered
Major or minor adjustments can be implemented and delivered quickly.
Meet the Experts
Our Team
Prof. Tavs Jorgensen (Co-founder, Technical Director)
Leads the overall direction of ACT, driving both technical strategy and industry engagement. Tavs works closely with manufacturers and partners to identify opportunities, develop projects and deliver tooling solutions grounded in real production needs. He brings deep experience across ceramic production, tooling design and digital manufacturing from both industry and academia.
Dr Michael Joyce Badea (Co-founder, Computational Design Lead)
Leads digital design, automation and optimisation workflows, specialising in CAD, custom scripting and computational design methods. Michael bridges digital development and manufacturing constraints to deliver efficient, production-ready tooling solutions.
Meet the Experts
Our Team
Sonny Lighfoot (Co-founder, Tooling & Production Lead)
Oversees tooling production and manufacturing delivery, with experience in ceramic tooling, product design, and additive manufacturing. Sonny ensures that digitally designed tooling performs reliably on the factory floor and meets production requirements.
Juliet Lennox (Commercial & Operations Manager)
Manages commercial and operational activities, supporting projects through to delivery. Juliet ensures research-led tooling solutions are translated into clear scopes, transparent pricing and reliable execution for industry partners.
Partners and Future Goals
Our Ambitions
Advanced Clay Tooling has grown out of nearly eight years of work in digital tooling and ceramic production, shaped by close collaboration with manufacturers, engineers and designers. That experience has led to a clear focus on practical tooling solutions that work within manufacturing constraints and project timelines.
Our ambition is to become a leading supplier of short-run tooling for the brick and ceramics industry. By supporting manufacturers with faster, more flexible tooling, we aim to make short-run and specialist products commercially viable, enabling a broader range of production without the cost and rigidity of traditional tooling. This supports a stronger ceramics sector, reduces reliance on importing heavy ceramic components from overseas, and opens new opportunities for manufacturers.
Our aim is simple: to unlock a richer world of architectural detail through ceramics.
Testimonials
Who We’ve Worked With
Who We Are
