The software tools used for designing and simulating the performance of the moulds produced at MORFI are Pro-E Creo3 and NX-8, where the solid modelling and initial simulation runs are performed. A TESA 3-axis CMM machine with tilting head and touch probe is used as well as a FARO portable arm-type coordinate measuring machine (CMM) equipped with a touch probe for accurate measurements over a working sphere of 2m in diameter and a laser scanner for rapid inverse engineering applications. Rapid prototyping in plastic on a FORTUS RP machine may follow to produce tangible 3-D prototypes for design evaluation, particularly when reverse engineering is performed. Thermal, flow, stress and kinematic simulations of the mould are then carried out to optimise various aspects of the mould operation and its proper and fault-free service life. Parts which are subjected to wear and corrosion are designed as spares, which share strict tolerances in order to match in the mould assembly.