Injection Mold Making

Overview

Injection mold making is the foundation of successful plastic manufacturing. Our tooling division designs and manufactures high-precision injection molds for thermoplastic components, serving automotive, medical, electronics, and consumer product industries worldwide.

With 20+ years of mold making experience, our 50-person tooling team produces molds ranging from simple single-cavity tools to complex multi-cavity production molds with hot runner systems. All molds are DFM-optimized and production-proven before delivery.

Mold Making Capabilities

Parameter	Capability	Application
Mold Size	Up to 2000 × 1500 × 800mm	Small to large molds
Mold Weight	Up to 15 tons	Various sizes
Cavity Count	1 – 128 cavities	Prototype to mass production
Machining Accuracy	±0.005mm	High-precision tooling
Surface Finish	SPI A1 – C3, VDI 3400	Mirror to textured
Mold Life	500K – 1M+ shots	Long-term production

🔧 Mold Manufacturing Process

Step 1: DFM Analysis

Our engineers analyze your 3D CAD files for manufacturability, suggesting optimizations for gate location, cooling channels, ejection, and part quality. This upfront analysis prevents costly mold revisions later.

Step 2: Mold Design

Using UG NX and Moldflow simulation, we design the complete mold structure including cavity/core, runner system, cooling channels, ejection system, and mold base. 3D mold designs are shared for customer approval.

Step 3: Material Selection

Mold steel is selected based on production volume and plastic material: P20 for low volume, H13 for medium volume, S136/420SS for high volume or corrosive materials.

Step 4: CNC Machining

High-speed CNC machines rough and finish machine cavity and core inserts. Our DMG Mori and Makino machines achieve ±0.005mm accuracy with excellent surface finishes.

Step 5: EDM & Wire Cutting

Electrical discharge machining creates fine details, sharp corners, and textured surfaces. Wire EDM produces precision holes and complex profiles.

Step 6: Polishing & Texturing

Skilled polishers achieve mirror finishes (SPI A1) or apply customer-specified textures (VDI 3400 standards). All finishes are verified under controlled lighting.

Step 7: Mold Assembly & Testing

Mold components are assembled and tested on our injection molding machines. T1 samples are produced, measured, and shipped for customer approval.

📦 Mold Types

By Runner System

• Cold Runner Molds: Cost-effective, suitable for most applications
• Hot Runner Molds: No material waste, faster cycling, higher initial cost
• Insulated Runner Molds: Hybrid approach for specific applications

By Cavity Count

• Single-Cavity Molds: Low volume, large parts, multiple materials
• Multi-Cavity Molds: High volume production, identical parts
• Family Molds: Multiple different parts in one mold (assembly kits)

By Special Features

• Insert Molds: For overmolding metal inserts or existing parts
• Two-Shot Molds: Rotary molds for multi-material parts
• Stack Molds: Double production capacity without larger machines

🎯 Mold Steel Selection

Steel Grade	Hardness	Mold Life	Application
P20	28-32 HRC	100K – 300K shots	Low volume, prototypes
718H	33-37 HRC	300K – 500K shots	Medium volume
H13	48-52 HRC	500K – 800K shots	High volume, abrasive materials
S136/420SS	48-52 HRC	800K – 1M+ shots	Corrosive materials, high polish

🔍 Quality Control

• 3D Scanning: Complete mold cavity verification against CAD
• CMM Inspection: Critical dimensions verified (±0.002mm accuracy)
• Pressure Testing: Cooling channels tested at 10 bar pressure
• Trial Molding: Minimum 100 shots to verify mold performance
• Sample Measurement: T1 samples fully measured and reported
• Surface Verification: Polish and texture verified under controlled lighting