Professional answers regarding precision mold design and manufacturing

There are significant differences between precision stamping molds and precision injection molds in terms of process principles, applicable materials, and application scenarios:

Process Principles: Stamping molds use a press to apply pressure to make metal sheets undergo plastic deformation. Injection molds use an injection machine to inject molten plastic into the mold cavity for cooling and shaping.

Applicable Materials: Stamping molds are mainly used for metal materials (such as stainless steel, copper, aluminum, etc.). Injection molds are mainly used for plastic materials (such as PP, ABS, PC, etc.).

Product Characteristics: Stamped parts usually have good strength and electrical conductivity. Injection - molded parts are lightweight, have good insulation, and can achieve complex shapes.

Application Fields: Stamping molds are widely used in automotive parts, electronic connectors, etc. Injection molds are mostly used in consumer electronics casings, medical devices, etc.

The manufacturing precision of our precision molds can reach the following levels:

• Dimensional accuracy: ±0.01mm (for general requirements), ±0.005mm (for high - precision requirements)
• Surface roughness: Ra0.2 - 3.2μm (customized according to product requirements)
• Form and position tolerance: within ±0.01mm
• Repeatability accuracy: within ±0.005mm

To ensure high precision, we use advanced CAD/CAE/CAM technologies for design, and are equipped with high - precision CNC machining centers, precision wire - cutting machines, 3D automatic measuring instruments and other professional equipment.

We ensure the quality and service life of the molds through the following measures:

• Material selection: High-quality mold steel (such as SKD11, DC53, NAK80, etc.) is selected according to product requirements, and strict material inspection is carried out.
• Heat treatment process: Vacuum heat treatment is adopted to ensure hardness uniformity and dimensional stability.
• Precision machining: High-precision CNC equipment is used, and the machining process regulations are strictly implemented.
• Quality inspection: Equipped with 3D automatic measuring instruments, projectors and other testing equipment to conduct comprehensive inspections on key dimensions.
• Test mold verification: Professional technicians conduct test mold debugging to ensure that the mold performance meets the standards.
• After-sales service: Provide regular maintenance guidance to extend the service life of the mold.

Under normal circumstances, the service life of our precision stamping molds can reach more than 500,000 times, and the service life of precision injection molds can reach more than 1 million times.

• Precision stamping molds: 15-45 days (depending on the complexity).
• Precision injection molds: 20-50 days (depending on the complexity).

The development cycle includes the following stages:

• Requirements analysis and technical review: 2-5 days.
• Mold design and confirmation: 5-10 days.
• Mold part processing: 10-30 days.
• Assembly, debugging and test molding: 3-7 days.
• Quality inspection and delivery: 1-2 days.

• Product structure optimization: Analyze the rationality of the product structure and propose improvement plans to improve molding efficiency and product quality.
• Mold structure optimization: Optimize layout design, runner systems, ejection mechanisms, etc., to improve mold stability and service life.
• Material selection suggestions: Recommend suitable materials according to product performance requirements to balance cost and performance.
• Process parameter optimization: Provide optimal molding process parameters to ensure stable product quality.
• DFM analysis: Conduct design for manufacturability analysis to identify potential problems in advance and propose solutions.

• CAD/CAE/CAM integration: Using software such as UG, Pro/E, and AutoCAD for design, and Moldflow for mold flow analysis.
• Five-axis linkage machining: Equipped with multiple five-axis CNC machining centers to achieve high-precision machining of complex curved surfaces.
• Precision wire cutting: Adopting slow wire cutting technology, with a machining accuracy of ±0.002mm.
• EDM (Electrical Discharge Machining): Possessing mirror EDM capabilities, with a surface roughness of up to Ra0.1μm.
• Laser welding: Used for mold repair, with fine weld seams and small deformation.
• Reverse engineering: Conducting product mapping and mold repair through coordinate measuring and 3D scanning technologies.

• Appearance inspection: The mold surface has no obvious defects, and the marks are clear and complete.
• Dimension inspection: Using a coordinate measuring machine to inspect key dimensions to ensure they meet the requirements of the drawings.
• Test mold verification: Continuously producing 100-300 products to check the stability of product quality.
• Function test: Verifying that mechanisms such as ejection, core pulling, and cooling operate smoothly.
• Life test: Conducting a certain number of stamping or injection molding tests to verify the mold life.
• Document delivery: Providing complete technical documents, including drawings, inspection reports, user manuals, etc.

• Warranty service: A 12-month warranty period is provided after the mold is delivered, with free repairs during the warranty period.
• Technical support: 7×24-hour technical consultation service and remote assistance to solve production problems.
• On-site service: Dispatching engineers to the customer's site for installation, commissioning or maintenance when necessary.
• Spare parts supply: Long-term supply of vulnerable parts and spare parts for molds.
• Training service: Providing training on mold use and maintenance for customer operators.
• Upgrading and transformation: Providing mold modification and upgrading services according to product change requirements.

• Mold complexity: The more complex the structure and the higher the precision requirements, the higher the cost.
• Mold size and specifications: Larger molds require more materials and processing hours.
• Material selection: High-end mold steel is more expensive but has excellent performance.
• Production batch: Mass production can amortize the cost of a single set of molds.
• Technical requirements: Special process requirements will increase manufacturing difficulty and cost.
• Delivery requirements: Urgent projects require more resources, and the cost increases accordingly.

• Rapid response mechanism: A dedicated emergency order processing channel is set up to provide a preliminary plan within 2 hours.
• Resource allocation: Prioritize the deployment of technical personnel and production equipment to ensure project progress.
• Parallel operation: Start some processing procedures while confirming the design to shorten the overall cycle.
• Overtime production: Arrange overtime reasonably to speed up project execution.
• Supply chain coordination: Establish strategic cooperative relationships with suppliers to ensure timely delivery of materials.

• Design stage: Fully consider production environment factors and conduct DFM analysis and mold flow analysis.
• Material control: Strictly screen high-quality mold materials to ensure material uniformity and stability.
• Processing accuracy: Adopt high-precision equipment and strict process regulations to ensure the matching accuracy of each component.
• Heat treatment: Use advanced vacuum heat treatment technology to ensure hardness and dimensional stability.
• Test mold verification: Conduct sufficient test mold tests to verify the stability of the mold under different conditions.
• Quality control: Establish a sound quality management system to monitor each production link.

• OEM/ODM services: Provide OEM or original design manufacturing services according to customer needs.
• Technical cooperation: Jointly develop new products with customers and share technical and market resources.
• Long-term cooperation: Sign annual framework agreements to enjoy preferential prices and priority services.
• Global services: Support cross-border cooperation and provide multilingual technical support and logistics services.
• Customized services: Provide personalized solutions according to customers' special needs.