What is injection molding tool

Injection molding tool, also known as a injection plastic mold or injection die, is a specialized tool used in the injection molding process to produce plastic parts and components. This is similar to high pressure die casting process.

Injection molding process which is injecting molten plastic material into an injection mold cavity, then it cools and solidifies to get the shape according to designed mold. The injection molding tool is a crucial component in molding process, and it is very complex tool which need professional manufacturers to make it.

Key components of an injection molding tool include:

To make the injection molding tool is very complex, if you require injection molding tool for your project, we suggest you find a manufacturer to help you, because this must be some professional injection molding tool manufacturer to make this whole jobs, below are some of main components in an injection molding tool:

Mold Base: The mold base is the structural foundation of the injection molding tool, providing support for the cavity, core, and other components. It often includes features for mounting the mold onto the injection molding machine. without mold base you cannot start injection molding process,

Cavity and Core: The mold is typically made up of two main parts – the cavity and the core. These parts fit together to create the final shape of the molded product. Of course there aer many small components in the cavity and core, surface insert pins, sleeve pins, screw, slider or lifters etc.

Runner System: The runner system consists of channels and gates that allow the molten plastic to flow from the injection molding machine into the mold cavity. It helps distribute the plastic material evenly throughout the injection molding tool.

Cooling System: The cooling system is integrated into the injection molding tool to control the tool temperature during the molding process. Proper cooling is essential for achieving consistent part quality and cycle times.

Ejector System: After the plastic has cold and solidified in the mold cavity, the ejector system is used to push or eject the finished part out of the injection molding tool. This part removal is a critical step in the overall injection molding process.

Injection molding tools can be complex and are typically custom-designed for specific parts. The choice of materials for the mold depends on factors such as the type of plastic being used, production volume, and the desired characteristics of the final product. Common materials for injection tools include steel and aluminum.

Types of Injection Molding Tools

There are many types of injection molding tools, each type of injection molding tool is suitable to different type of parts and requirements. The choice of injection molding tool tool type depends on factors such as the complexity of the part, volume requirement, part size, material properties, and cost considerations. Below are some common types of injection molding tools:

1. Single Cavity and Multi-Cavity injection molding tools:
   • Single Cavity Tools: These injection molding tools produce one part per cycle/cavity. They are suitable for low-volume production or large part size.
   • Multi-Cavity Tools: These tools have multiple cavities, allowing the production of multiple parts in each molding cycle. They are used for high-volume production to increase efficiency and reducing the unit price.
2. Family Tools:
   • Family tools are a type of multi-cavity mold that produces different parts simultaneously. This is very useful for some small parts and low volume of molding parts, so that could save the tool cost.
3. Hot Runner Tools:
   • Hot runner tools use a system of heated channels (hot runners) to inject molten plastic directly to each cavity. This eliminates the need for a sprue and runner system, reducing material waste and cycle time. this is normally used in high volume production and very big size of parts, some of molds may have multiple hot drops.
4. Cold Runner Tools:
   • Cold runner tools is runner system where the molten plastic flows through cold channels, normally throw the spure to cavity and core, which solidify with the molding part together. Cold runner tools are used for the low volume production requirements.
5. Insert Tools:
   • Insert tools or insert molding is molding the metal insert or other solid material together with molded parts, sometime we may simply called overmolding. This is useful for incorporating features like threaded inserts or reinforcing elements.
6. Overmolding/Two-Shot Tools:
   • Overmolding is similar to the insert mold, but overmolding is molded two type of plastic molding into one solid parts, the second shot normally are soft material such as TPE. Two-shot molds enable the injection of two different materials or colors in a single molding cycle, two shot molding requirement 2k injection molding machine which is very expensive.
7. Prototype Tools:
   • Prototype tools are used for low-volume production of prototype parts to test and validate designs before full-scale production. Sometime can use 3D printing prototypes of CNC machining prototypes instead of this tools.

To choose the type of injection molding tool which depends on the specific requirements of the project, if you are not know which tool should use for your project, contact us for a help,  we will select the most appropriate tooling solution for your needs.

Design Considerations for Injection Molding Tools

Designing injection molding tools need to think about various of factors to ensure the production of high-quality plastic parts. Good design come out with good injection molding tools, so design is one of the key factor to make high quality and long life time injection molding tools, Below are some key design considerations for injection molding tools:

1. Part Design:
   • Good part design will make a success injection molding tool more easy, balance wall thickness, good rid design, draft angle, undercuts etc. those factors should be considering in the part design
2. Material Selection:
   • The choice of mold material depends on factors such as the type of plastic being used, production volume, and expected tool life. Common materials for tools include tool steel such as 1.2344,1.2343, S136, H13, pre-hardened steel like P20, 738H, NAK80, and aluminum like 7075.
3. Cooling System:
   • Cooling channels is one of other important factor that need to think about during injection molding tools design, good cooling will have very good part quality, surface less deformation issues, shot cycle time etc.
4. Gate Location Design:
   • The gate is feeding system in the injection molding tools. Proper gate design is essential for achieving optimal part quality, minimizing stress, reducing the air trap or sink marks.
5. Runner System:
   • The design of the runner system, which includes the channels through which plastic flows in the mold, good runner size will be more easy to fill the part, and reduce the part distortion or sink issues.
6. Ejection System:
   • The ejection system is responsible for demoudling the molded part from the mold core. proper ejection system design will avoid the part damage, warpage, and stress marks, etc., 
7. Venting:
   • Proper venting ensures the escape of air and gases from the mold cavity during injection. Good venting is always needed to make good part
8. Draft Angles:
   • Draft angles are essential for facilitating part ejection from the mold. They help prevent scratch issue from mold surfaces. Specially for some texture surface requirement. Adequate draft angles should be incorporated based on the material and part geometry.

Above are some general factors that must be think about during injection molding tools design, there will be more factors that need to consider, if you need injection molding tool, find a professional injection molding tool maker is the only way to success your project.

Cost Considerations in Injection Molding Tooling

Cost considerations in injection molding tooling are crucial, normally any of molding tools will be very high, this including high pressure aluminum die casting mold, zinc or magnesium die casting mold, Continuous stamping mold, gravity die casting mold, as they significantly impact the overall economics of the manufacturing process. Here are key factors to consider when evaluating the costs associated with injection molding tooling:

1. Material Selection:
   • The choice of material for the injection molding tool plays a significant role in cost. High-quality tool steels are more expensive than less durable materials like aluminum, but they may offer longer tool life and reduced maintenance costs over time, some of high cost tool steels such as 1.2343, H13, 8407 (die casting mold), Low cost steel such as P20, 738H etc.
2. Tooling Complexity:
   • More complex part design then more cost on the injection molding tools, if can reduce some of action features that will reduce the some, improving the part design can reduce the injection molding tool cost.
3. Number of Cavities:
   • Multi-cavity tools can be more cost than single cavity mold, but if you have more than 2 parts in one project, then Multi-cavity tools can reduce the cast for this project for you.
4. Tool Size:
   • Small tool size will be less expensive the big size tools, because big size tools requires more material and machining cost.
5. Surface Finish:
   • Normal polishing will be less than high polishing tools, and some texture surface will increase the injection molding tool cost.
6. Tool Steel Grade:
   • Different grades of tool steel have varying costs. Pre-harden steel like P20, 1.2738H will less cost then harden steel (1.2344, H13 etc.), because harden steel will need heat treatment and second CNC machining cost.
7. Tolerances and Precision:
   • Tighter tolerances and higher precision plastic molding parts will requirement high precision injection molding tools. this will increase the injection molding tool cost.
8. Testing cost:
   • Mold try will be the cost as well, some of molds requirements many times trials to get final release, so this will increase the cost as well.

Above are some of general injection molding tools cost. There will be some more cost, surface modification, injection molding tools adjusting cost, and so one.

Applications of injection molding tool

Injection molding tools are used to various industries for the production of plastic parts and components. We can say everything you needs injection molding tools. Below are some common applications of injection molding tools:

1. Automotive Industry:
   • There are many automotive parts that requires injection molding tools. including interior parts, dashboards, door panels, exterior body panels, bumpers, door handle, seat cover, and various other components.
2. Consumer Goods:
   • Many consumer goods are produced using injection molding, including household items such as kitchenware, storage containers, toys, and electronic device casings. And hair straightener manufacturer will use injection molding tools for the high speed hair dryer housing or hair straightener casings.
3. Medical Devices:
   • Injection molding tools are used for some medical machines or some medical tools. including syringes, vials, IV components, diagnostic equipment housings, and other medical disposable parts .
4. Electronics and Electrical Components:
   • The electronics industry utilizes injection molding tools for the production of casings, connectors, electric housings such as smartphones, computers, routers, and power adapters.
5. Packaging Industry:
   • Injection molding is widely used in the packaging industry for the production of plastic bottles, caps, containers, and packaging components for food, beverages, beauty, makeup, and personal care products.
6. Appliances:
   • There are many injection molding tools sued in household appliances, such as washing machine parts, refrigerator components, and vacuum cleaner housings.
7. Aerospace Industry:
   • In the aerospace sector, injection molding tool is used to produce lightweight and high-strength components, including interior and exterior aircraft parts etc.
8. Construction:
   • Injection molding is employed in the construction industry to produce components such as pipe fittings, cable management systems, electrical junction boxes, and insulation materials.
9. Toys and Games:
   • The toy industry extensively relies on injection molding for producing a wide variety of plastic molding toys, building block, and game components.

We can say everything you need injection molding tools, in above list there are only a few of industries, but there are more than that like instruction, sport, travelling etc.

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Our injection molding tools and die castings across various industries, including automotive, consumer electronics, medical, and industrial equipment, we tailor our solutions to meet their specific needs, providing custom designs that align with their unique requirements.

Whether you require a single plastic mold or aluminum die casting service, we possess the expertise and resources to deliver outstanding results. Contact us today for a quote.