Custom Moulds | Mould Design & Manufacturing Services

Custom moulds turn product ideas into repeatable, high-quality parts. Whether you need a single prototype cavity or a 4-cavity production tool for injection, compression or blow moulding, reliable mould design and precision manufacturing determine part performance, cost and time-to-market. This article explains our end-to-end process (DFM, prototyping, validation, production), shows an anonymized case study with measured test data, and provides an SEO-friendly content structure that answers common buyer intents: “How to”, “Buy”, and “Review/Compare”.

Why accuracy in mould design matters 

Key engineering goals 

• Tolerance control and dimensional stability

• Material flow (gate, runner, venting) to avoid short shots/warp

• Injection/compression cycle optimization to reduce cycle time and scrap

Business outcomes 

• Lower per-part cost at scale

• Reduced assembly rework and warranty claims

• Faster first-time-right launches

Our process — step-by-step

(Information intent — includes actionable steps and what buyers look for.)

1. Requirements & specification capture 

   • Confirm part function, target polymer/metal, surface finish, projected volume, and cycle time.

2. Design for Manufacturability (DFM) review 

   • Draft part and mould proposals (2–3 iterations). Key checks: wall thickness, draft, ribs, bosses, tolerances.

3. Prototype tooling & rapid validation

   • Aluminium or soft-steel prototype mould, 10–500 parts for fit/form/function testing.

4. Production tooling & trial run 

   • Hardened steel mould, full trial; run samples, measure critical dimensions, perform mechanical testing.

5. Quality control & process qualification 

   • Create Control Plan and SPC charts; provide inspection reports (CMM, visual, functional tests).

6. Volume manufacturing & continuous improvement 

   • Optimize cycle times, run rate planning, preventive maintenance schedule.

Representative case study (anonymized) — measurable results 

Client: Automotive sensor housing (PA66 GF30), 2-cavity steel mould.
Objective: Reduce warp and bring first-pass yield >95% at target cycle time ≤28s.

Actions performed

• DFM reduced local wall thickness from 2.5 mm to 2.0 mm in problematic ribs.

• Gate location moved from edge to center to improve flow balance.

• Added cold slug well and optimized venting.

Measured outcomes 

• First-pass yield: 98.2% (vs 86.5% before changes)

• Average cycle time: 26.5 s (down from 34 s)

• Dimensional Cpk on 3 critical dimensions: ≥1.67 across 500 samples

• Rework rate: <0.5%

Notes: sample sizes, measurement methods and inspection tools (CMM with 2 µm resolution) are documented in the trial report provided with delivery.

Technical details buyers ask for 

Materials & finishes 

• Tool steels: P20, H13, S136, 1.2344 — specify based on abrasion, polishing need and production volume.

• Surface finishes: SPI A/B for glossy parts, textured finishes with sample panels provided.

Tolerances & inspection 

• Standard tolerances: ±0.05 mm for most thermoplastic components; tighter tolerances via post-mold machining if required.

• Inspection: ISO 2859 sampling, CMM reports, functional testing.

Pricing & lead times 

• Prototype aluminium tool: typical build 7–14 business days; tooling cost depends on cavities and complexity.

• Hardened steel production tool: typical build 6–10 weeks depending on complexity and steel lead time.

• Cost drivers: cavity count, steel grade, undercuts, lifetime expectation (×100k to millions), EDM/precision surface requirements.
  Include line item quotes: tooling, validation, run-off, and per-part manufacturing cost at given volume.