Tooling & Mold Engineering
Mold Capabilities — Injection, Die Casting, LSR, Extrusion & Stamping
Detailed capabilities for prototype and production tooling. We design, build, try out and support molds and dies across multiple processes with attention to tool life, maintainability and cost amortization.
- Prototype → production tooling strategies (aluminum prototype, hardened steel, multi‑cavity)
- Specialty tooling: hot runner, valve gate, family molds, cavity inserts, and co‑injection
- Lifecycle services: PM, spares, repair, refurbishment and emergency lanes
Injection Molds — Prototype & Production
Die Casting Dies — Aluminum & Zinc
LSR & Rubber Molds
Injection Mold Capabilities
We design prototype aluminum molds for quick validation and hardened steel production molds (P20, H13, S7) for high cycle life. Capabilities include multi‑cavity molds, hot runner systems, valve gates, family molds, conformal cooling simulation, mold flow analysis, and insert/overmold tooling.
Key features
Multi‑cavity & family tooling up to 16+ cavities where practical
Hot runner integration, valve gate control and thermal balancing
Multi‑shot & overmold tooling, insert molding provisions
Conformal cooling and optimized venting for cycle reduction and warp control
Tryout & validation
We perform trial runs, first article inspection (FAI), CMM sampling and process window documentation (temperatures, cycle time, clamp force). We deliver sample galleries and recommended inspection plans for production release.
Die Casting Die Capabilities (Aluminum / Zinc)
Cold‑chamber dies for aluminum and hot‑chamber dies for zinc with careful gating and cooling design. We offer vacuum/low‑pressure casting tooling to reduce porosity and deliver tighter mechanical integrity for housings and pressure‑bearing components.
Process & tooling features
Die design with cooling circuits, venting and ejector strategies
Vacuum assist and low‑pressure options to minimize gas porosity
Post‑cast CNC finishing fixturing integrated into die acceptance plan
Rubber & LSR Mold Capabilities
Stainless and hardened tooling for LSR injection, compression and transfer molds. We polish cavities for cosmetic surfaces, design venting for proper cure, and provide tooling integrated with post‑cure ovens and automated degating for consistent part quality.
Highlights
- Metering and shot traceability for LSR process control
- Insert & overmold capabilities combining elastomer with rigid substrates
- Cleanroom molding readiness and medical‑grade tooling options
Extrusion Die Design & Tooling
Custom die engineering for aluminum profiles and elastomer/silicone extrusions. Services include die CAD, mandrel design, vacuum sizing, die swell compensation, co‑extrusion tooling and prototype die trials to validate dimensional stability and section consistency.
Capabilities
- Co‑extrusion for multi‑durometer or bonded profiles
- Die maintenance programs and spare landings
- Cut‑to‑length automation and downstream machining integration
Progressive & Transfer Stamping Tooling
Progressive dies for high‑volume multi‑feature parts and transfer dies for larger blanks with multiple forming stages. Tooling includes die lock, pilot systems, strip layout, station sequencing, coining and integrated tapping or riveting stations to reduce secondary operations.
Engineering focus
- Strip & blank optimization, material utilization
- Progressive station design to balance forming and reduce scrap
- In‑die quality checks and automated ejection systems
Casting Patterns & Forging Dies
Pattern making (wood, epoxy, 3D printed master), wax tooling for investment casting and forged die design for closed‑die forging. We perform gating and riser simulation, directional solidification studies and iterate pattern geometry during prototype runs.
Additions
- Investment & sand pattern fabrication with rapid prototyping
- Forging die flow and flash trimming plan with heat treatment post‑process
- NDT readiness (CT/X‑ray and ultrasonic) for critical castings
Jigs, Fixtures & Welding / FSW / Laser Fixtures
Precision fixtures for machining, automated welding, FSW and laser brazing. Our fixture designs prioritize quick changeover, locator accuracy and integrated sensors to enable automated in‑process checks and reduce setup time on production lines.
Typical features
- Quick change pallets, locator pins and datum references
- Integrated temperature or pressure sensors for process monitoring
- Robotic end‑effector interfaces and safety interlocks
Tool Life, Maintenance & Repairs
Planned preventative maintenance (PM) minimizes unscheduled downtime. We provide PM schedules, spare insert programs, repair & refurbishment lanes, and emergency response SLA options. Maintenance services include EDM rework, insert replacement, profiling and recoating.
Preventative maintenance
Regular dimensional checks, coolant channel cleaning, polish cycles and functional run checks recorded in tooling logs and recommended PM intervals tied to shot counts
Repair & refurbishment
EDM, welding rebuilds, recoating (TiCN/TiN), re‑hardening and resurfacing to restore tool functionality and extend lifecycle.
Tryout, First Article & Quality Gates
Tool tryout includes sample runs, FAI (First Article Inspection), CMM reports, surface finish checks and process window definition. We deliver FAI packages, recommended SPC plans and operator instructions required for production handover.
Typical tryout deliverables
- FAI report with dimensional CMM data
- Sample gallery and surface finish verification
- Process window and initial SPC plan
- Tool acceptance checklist and maintenance recommendations
Tool Materials & Surface Treatments
Standard tool steels (P20, H13, S7) are selected per application with nitriding or cryo treatments where beneficial. Surface coatings (TiN, TiCN) and nickel plating for cooling passages increase wear resistance and corrosion protection. We specify treatments based on run rates, abrasive plastics and environmental exposure.
P20
General purpose, pre‑hardened steels for injection mold bases
H13
Hot work steel for core/cavity demanding thermal cycles
S7
Shock resistant tool steel for progressive dies and impact work
Coatings
TiN/TiCN, DLC, nickel plating for channels and wear surfaces
Quality, Testing & Inspection
We deliver FAI packages, CPK capability analysis, visual & dimensional inspections, material certificates and functional testing. In-line vision systems, CMM sampling, and SPC controls ensure consistent quality across production batches.
Regulatory & traceability
Support for traceability, lot coding, material MTRs, and documentation required for medical, automotive and aerospace programs.
Finishing, Decoration & Assembly
Secondary services: painting, pad printing, silk screening, laser marking, ultrasonic welding, adhesive bonding, heat staking and full electromechanical assembly with connectors, wiring and final functional test.
Packaging & global fulfillment
Custom packaging, kitting, labeling and DDP shipping options with USA warehousing to support after-sales and JIT programs.
Tooling Cost Models & Amortization
We provide transparent tooling cost models that compare prototype aluminum molds vs hardened steel, single vs multi‑cavity tradeoffs, and maintenance/spare strategies. Our amortization reports show break‑even piece counts and recommended tooling lifetimes based on expected volumes.
| Tool Type | Typical Tool Cost | Shot Life / Notes |
|---|---|---|
| Aluminum prototype mold | Low (USD thousands) | Quick turn; limited life; best for validation |
| Hardened steel injection mold | Medium–High (USD tens to hundreds of thousands) | High shot life; suited for long runs & multi-cavity |
| Die casting die | High (USD tens to hundreds of thousands) | Requires service; vacuum options increase cost |
| Progressive stamping die | High (USD tens to hundreds of thousands) | Optimized for millions of parts/year |
Representative Tooling Projects
Multi‑cavity PEEK Connector Molda
16‑cavity hot runner mold for high‑temperature PEEK connectors with family gating and integrated insert stations to eliminate secondary assembly steps.
Die Cast Housing Die — Vacuum Assisted
Vacuum die for aluminum housing with post‑machined sealing faces and integrated cooling to meet automotive leak and porosity specs.
Frequently Asked Questions
How do I choose between prototype and production tooling?
Prototype tooling is recommended to validate geometry and function quickly at low cost. Move to hardened production tooling when volumes, part complexity and cosmetic requirements justify the CAPEX. We provide break‑even analysis to help decide.
What determines mold lead time?
Complexity, cavity count, required coatings/heat treatments, EDM schedules and polish work. Typical ranges: prototype 1–4 weeks; production hardened molds 6–16+ weeks.
Can you supply spare inserts and a PM program?
Yes — we recommend and supply spare cores, inserts and plan periodic PM to extend life and reduce unplanned stops. We can host tooling for managed maintenance or ship spares to customer sites.
What emergency support is available for down tools?
We operate prioritized repair lanes, emergency EDM and rapid replacement insert fabrication to minimize line downtime — SLA options available for critical programs.
Start Your Mold Project
Upload your part CAD, target volumes and expected finishes. We’ll return a tooling recommendation, estimated lead times and an amortization model — typically within 24 business hours.
