Injection Molding Mold Types: Tooling For Custom Parts

injection mold, mold building

There are lots of injection molding mold types. Common injection molding mold types include single-cavity, multi-cavity, family, hot runner, cold runner, and more, which are generally aluminum molds or steel molds.
Injection molding mold types reflect the diversity of the injection molding process and can meet various production requirements and product designs.
Sungplastic is an injection molding mold manufacturer and can provider different injection molding mold types for you.
If you are looking for mold fabrication solution, please read more.

injection molding mold types

Low/High Cavitation

In injection molding, picking between low or high cavitation molds matters a lot. It affects how much you can make, the cost of the molds, and how efficient you are. Knowing the differences between these molds is key for making the most of your investment and meeting market needs.

Low cavitation molds have 1 to 4 cavities. They’re great for small batches or complex parts. They cost less upfront and can handle tighter tolerances, perfect for prototypes or special items. But, they can’t make as much as high cavitation molds.

High cavitation molds, with 8 to 96 or more cavities, are for making lots of parts. They boost production capacity, making things faster and cheaper per part. The initial tooling costs are higher, but the savings over time make them good for big orders.

Mold Type Cavities Production Volume Tooling Costs Cycle Time
Low Cavitation 1-4 Lower Lower Longer
High Cavitation 8-96+ Higher Higher Shorter

Choosing between low or high cavitation molds depends on your project’s needs. Consider the production volume, part complexity, and your budget. By weighing these, you can pick the right mold for your business goals and a successful molding process.

Family Mold

A family mold shares a single mold base but features two or more distinct cavities, enabling the production of different parts simultaneously or with the option to isolate production to specific cavities using shut-offs. For optimal results in molding, it’s advisable for the parts to be similar in size, shape, resin type, and expected production volumes, especially if the intent is to manufacture all parts concurrently. Automation may be required to separate the pieces during or after production.

If mold cost is a significant consideration and production volumes are low, a family mold can offer cost savings and versatility.

 

 

 

family mold

Unscrewing Molds

Also known as a threaded mold or rotating core mold, it is one of injection molding mold types, specifically designed to create parts with threaded features, such as screw threads. Unscrewing molds represent the most common method for incorporating threaded holes into plastic parts. These molds employ automated systems with small drive mechanisms (such as rack & pinion, electric, or hydraulic motors) linked to the manufacturing process. These mechanisms rotate threaded features to extract undercut features. Threads can be either internal or external, and the extraction process is synchronized with the press cycle.

Multi-shot/multi-component tooling allows product designers to use two or more dissimilar materials within the same part during a single cycle. Various factors, including different physical properties or purely aesthetic considerations, may justify using different materials. Such molds often employ multiple manifolds within a single tool. Multi-shot tooling can provide an elegant solution for complex products and accommodate color changes within a product line.

Running multi-shot tooling requires specialized presses and molds. It may necessitate multiple machine nozzles, hot runner systems, and mold rotation. While we currently do not have multi-shot molding presses on our premises, we excel in designing and constructing these intricate tools, a skill we have honed over decades.

unscrewing molds

Hot Runner Molds

Hot runner molds employ temperature-controlled manifolds to significantly reduce or eliminate waste material (runners) during the molding cycle. Injection points can be located outside the part or directly into it. This approach can substantially enhance cycle times, as the sprue or runner system often dictates the mold cycle duration. Eliminating runners also saves valuable material.

Hot runner molds require a press-specific temperature controller, sized to match the manifold in the mold. Some maintenance costs associated with hot runner tools may be higher, but they often pay for themselves over time through material and cycle time savings. This is particularly relevant for applications involving expensive engineering-grade resins or high annual production volumes.

Cold Runner Molds

Cold runner molds represent a more conventional approach, utilizing sprues and runners to gate into the part. While this method is typically less complex, it may result in larger amounts of wasted material and slower production cycles. Depending on the application, a portion of the wasted material can be re-ground and re-processed for future use, but this might impact the physical properties of the resin.

Dealing with advanced, high-cost materials like engineering and medical-grade resins or facing constraints on regrind usage in your application may make a more efficient hot runner mold a preferable choice for your project.

Insulated Runner Molds

Insulated runner tools resemble traditional cold runner molds but incorporate cartridge heaters or other heating methods to create a surrounding layer of molten resin, forming an insulated “cull.” This achieves a similar effect to a hot runner system but at a lower cost, as it eliminates the need for a temperature controller. Additionally, it allows for quicker color and material changes. However, insulated runners may not be suitable for all materials and tend to be less compatible with demanding engineering-grade resins.

Two/Three Plate Molds

Three-plate molds are essentially cold runner molds, but the addition of a third plate in the runner system provides the flexibility to position the injection point virtually anywhere on the tool. This approach is usually more cost-effective than implementing a hot runner system. However, these molds often feature larger and more unwieldy runners, making automation a more challenging task.

Two Plate and Three Plate Molds

Composite Mold

Composite molds are one of the injection molding mold types used to manufacture composite parts that contain multiple different materials. These molds typically require precise control systems to ensure that different materials are injected in the correct locations and times to produce the final composite product.

Rotational Mold

Rotational molds are one of the injection molding mold types used to manufacture hollow or large plastic parts, such as tanks, barrels, and toys. These molds evenly distribute plastic powder inside the mold and then rotate the mold to melt and solidify the plastic inside, forming the desired shape.

Foam Mold

In the world of injection molding, foam molds are a standout. They make lightweight, insulating parts. These molds use a special structure to create parts that keep things cool and quiet. They’re in high demand in many fields, from cars to buildings.

What makes foam molds special is their ability to make a light, airy material. This material has a cellular structure. It’s lighter and better at keeping things cool, making it perfect for many uses.

In the car world, foam molds are used for things like dashboard inserts and door panels. These parts make cars more fuel-efficient and comfy. They also help keep the car quieter.

But foam molds aren’t just for cars. They’re also used in packaging and building. In packaging, they keep things cool. In building, they help make homes more energy-efficient and cozy.

Industry Applications Benefits
Automotive Dashboard inserts, door panels, headliners Lightweight, insulation, improved fuel efficiency, enhanced comfort
Packaging Containers, cushions Insulation, temperature-sensitive protection
Construction Building materials Thermal and acoustic insulation, energy efficiency

Foam molds are a great choice for making parts that are light and insulate well. They’re key for making things more sustainable and energy-efficient. As we look to the future, foam molds will play an even bigger role in many industries.

Temperature-Sensitive Mold

In the world of injection molding, temperature-sensitive molds are key. They help process materials that are sensitive to heat. These molds keep the temperature just right, ensuring the product’s quality.

Working with materials that change or degrade with heat is tricky. Temperature-sensitive molds have advanced systems to control the temperature. This keeps the material’s properties safe.

To control temperature, molds use heat-sensitive materials and special systems. They also have advanced monitoring. This precision is key for making high-quality parts.

Feature Benefit
Precise temperature control Enables the processing of heat-sensitive materials without compromising their properties
Advanced temperature monitoring and feedback systems Ensures consistent part quality and dimensional accuracy
Specialized heating and cooling systems Allows for rapid temperature changes and tight temperature tolerances

Using temperature-sensitive molds lets manufacturers fully use heat-sensitive materials. This opens up new design possibilities. It shows how injection molding technology keeps improving for precise temperature control and heat-sensitive materials.

Large Mold

In injection molding, large molds are key for making big plastic parts for industrial applications. They handle the tough job of making heavy-duty machinery and oversized components needed in many fields.

Big molds need special tools and skills to work right. They must stand up to high pressure and heat to shape plastic. Also, their size makes moving, setting up, and keeping them in good shape hard.

  • Construction, automotive, aerospace, and heavy equipment making often use large molds.
  • They help make big parts like car body panels, machine cases, and large products for homes.
  • Working with heavy-duty machinery and big molds needs careful planning to be efficient and save money.

Using large molds shows how flexible and strong injection molding is. It lets companies make the oversized components and heavy-duty machinery needed for many industrial applications.

Embossing Mold

In the world of injection molding, the embossing mold is a versatile tool. It allows manufacturers to create a wide range of surface texturingdecorative patterns, and functional finishes on plastic parts. This specialized mold design not only enhances the aesthetic appeal of products but also introduces practical advantages. These advantages can improve functionality and user experience.

Embossing molds work by imparting intricate surface features onto the molded plastic component. This process can be used for both decorative and functional purposes. Decorative finishes might include simulated leather, fabric, or wood grains. Functional finishes could incorporate anti-slip surfaces, perforations for ventilation, or even micro-structures for improved tactile feedback.

One of the key benefits of embossing molds is their ability to add value to a product. They elevate its visual appeal and tactile properties. This is especially advantageous in industries where design and user experience are crucial, such as consumer electronics, automotive interiors, and household goods. By incorporating these specialized surface features, manufacturers can differentiate their products, enhance brand identity, and create a more engaging and memorable user interaction.

Embossing Mold Applications Decorative Finishes Functional Finishes
Consumer Electronics Simulated Leather Anti-Slip Surfaces
Automotive Interiors Fabric Textures Perforations for Ventilation
Household Goods Wood Grains Micro-Structures for Tactile Feedback

By leveraging the capabilities of embossing molds, manufacturers can create plastic parts that not only meet functional requirements but also captivate the senses. This innovative approach to injection molding allows for the seamless integration of surface texturingdecorative patterns, and functional finishes. It elevates the value and appeal of a wide range of products.

How to Choose Injection Molding Mold Types

Choosing one of the right injection molding mold types is a critical decision that can significantly impact the quality, cost, and efficiency of your plastic product manufacturing process. Here are considerations to help you choose the appropriate injection molding mold types.

Clearly define your product’s specifications, including size, shape, material, color, design complexity and any special features or requirements. Complex parts may require specialized molds.

Consider the expected production volume of your product. This will influence the choice of mold type and construction.

Choose one of the most suitable injection molding mold types based on your product and production needs.

Select the appropriate injection molding mold types material based on factors like the type of plastic material you’ll be using, production volume, and expected tool life. Common mold materials include steel and aluminum.

Consider initial mold costs, production costs, and expected product lifespan. Different injection molding mold types and materials have varying costs. Balance cost considerations with quality and efficiency.

Some molds may have longer lead times for design, fabrication, and delivery. Ensure that the mold can be ready within your desired timeframe.

Sungplastic: Mold Fabrication Solution for You

Our mold fabrication solutions include:
Rapid tooling manufacturing
Rapid prototype mold fabrication
Injection mold fabrication
Thermoforming Tooling
Custom silicone molds manufacturing

We are good at manufacturing different injection molding mold type for producing custom parts. Besides, we also provide custom parts manufacturing services, like CNC machining, injection molding, 3D printing, casting and so on.

Contact us directly if needed! Hope our specialization can help with your project!

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