Efficient mold manufacturing process

Five-Step High-Efficiency Mold Development Process

1. Structural Design & Molding Solution

Engineers perform product structural analysis, defining parting surfaces, gate locations, and draft angles. Output includes Design for Manufacturability (DFM) reports with critical validations:  

① Injection system optimization (runner/gate design)  

② Cooling channel layout analysis  

③ Structural integrity validation through digital twin simulation  

Key deliverables: Multi-angle view drawings with tolerances (±0.01mm) and material selection reports 

2. Client Joint Review,Conduct cross-functional reviews with:  

① 3D model validation (STP/STEP files)  

② 2D drawing verification (ASME Y14.5 standards)  

③ Critical feature checks:   Parting line aesthetics ,Slide/skate movement clearance  ,Datum reference consistency  

Tools: Virtual assembly validation with CAD software 

3. Pre-Production Planning

① Establish priorities through engineering meetings:  

② Machining sequence: Core/cavity → Mold base → Components  

Special processes:  Spark erosion finishing (Ra 0.4μm) ,Nitriding treatment (HRC 50-55)  

③ Quality plan:  Critical dimensions (Cpk ≥1.67)  ,Appearance sampling (AQL 0.65)  

4. Modular Machining Implementation

Execute precision manufacturing using:  

① Rough machining (5-axis milling)  

② Mold base finishing (surface grinding)  

③ Core/cavity CNC/EDM (mirror finish)  

④ Component fabrication (CNC turning)  

⑤ Assembly & trial fitting (T0 trial within 28 days)  

Advanced techniques: Hybrid cooling channel machining 

5. T0 Trial & Quality Assurance

① Rapid die change technology reduces setup time by 40%  

② CMM inspection for critical features (dimensional accuracy ±0.005mm)  

③ Surface defect analysis (magnification 50X)  

④ Mold maintenance log system with:  500-shot polishingintervals,2000-shot lubrication checks  

Process Excellence Metrics 

Cycle time reduction: 30% through lean machining  

T0 pass rate: 98%+ via predictive analytics  

This methodology aligns with international standards (ISO 13849) and supports concurrent engineering principles for accelerated time-to-market.