RESIN TRANSFER MOLDING (RTM) PROVIDES AN ECONOMICALLY VIABLE PRODUCTION METHOD FOR SHORT AND INTERMEDIATE VOLUMES. THIS PAPER IS A CASE STUDY ON THE BUILDING OF A RTM TOOL TO PRODUCE HEADLIGHT BARS FOR BUSES. IT DETAILS USE OF A METHACRYLATE-BASED TOOLING RESIN HIGHLY FILLED WITH ALUMINUM. THIS UNIQUE SYSTEM FOR CREATING THERMALLY CONTROLLED MOLDS HAS NEGLIGIBLE SHRINKAGE AND A LOW COEFFICIENT OF THERMAL EXPANSION. THESE FACTORS, ALONG WITH LOW COST AND A SHORT DEMOLD TIME, REGARDLESS OF SIZE, ENABLE TOP QUALITY TOOLS TO BE BUILT QUICKLY AND ECONOMICALLY.