Large-Complex injection molds generally with big physical parameter (length & weight more than 1200mm & 10T accordingly) , multiple mechanical actions, challenge tolerance and extensively used to automotive, heavy truck, architecture,household appliance industries ect.

We have been developing a great many top-quality and large-complex automotive interior & exterior plastic toolings for Toyota, BMW, Mercedes and Honda ect. that meet and exceed even the most stringent standards relying on cutting-edge technology and state-of-the-art equipment s from tooling design to manufacturing. Our large-complex injection molds are most frequently used in presses , but not limited to 750T to 2200T

2K mold also referred to as double-shot, two color mold, dual-shot, multi-shot and over molding or insert molding, is a plastic molding process where injected two different plastic resins together in a single mold or two separated molds.

Over molding and insert molding some times are separated to two molds to balance cost and customer’s production capability. we will provide best evaluation to you for which ways based on your needs. Normally this two type of molds increases handling work if you set up two molds working on two single injection machines or working on one 2K machine without pick-up manipulator.

Generally recommend double-shot ,which reduce the amount of scrap, plastic material, cycle times, work-in-process(WIP) , assembly and driving mold & production down costs.

Collapsible Cores can dramatically increase production efficiency(mold cycle time can shorten 20~30%) on many plastic parts which requires internal threads, protrusions ,cut-outs or undercuts ect. It’s a breakthrough compared conventional unscrewing molds no matter for the applicable scope or production efficiency.

We have been developing some special structures over two decades, Collapsible Cores is one of typical unscrewing and retracting undercut solutions utilizing in injection toolings , which has expanded the capabilities of undercut molding more than any other retracting undercut solutions, also have established our reputation of unscrewing and retracting undercut injection mold fabrication.

We design and make collapsible core in-house in accordance with customer’s plastic part specification & production application, which is very economic in cost over Standard Collapsible Cores in marketing, but with high precise and reliable quality.

Die casting molds started out and upgraded from sand casting but it casts product with high mechanical performance than traditional casting and already evolved to variety of appliance with different material. Traditional casting principle is that filling molten metal into a mould that conventionally made by sand, salt or metal. After that it had gradually evolved to pressure die casting. In this way, the die-casting machine squeezes the molten metal into a mould cavity under high pressure and then holding metal material under pressure during solidification. Finally taking out the casted part from tooling after cooling. This kind of molds is suitable for very high rate production because of the fast solidification and automatic mold running under controlled of die casting machine. Many zinc, aluminum, magnesium, copper and it’s related alloys are cast using this method. Especially for zinc and aluminum alloys casting that extensively used to all kinds of industries, such mechanical, automotive, electrical, sport, toy fields.

In the two decades, we have been offering die-casting method and tooling service for clients from different industries, At Mold World our experienced engineers work with our customers to ensure the tooling design and manufacture are optimized for consistent quality and competitive cost.
we use cast simulation software(i.e. Flow-3D)which allows us to analyze the mold flow to assist tool design. We know precisely how to eliminate mold and casting process defects like air bubbles,porosity, entrained air (air trapping), and surface cold mark & shuts.

WHAT IS “IN-MOLD DECORATION and LABELING” ?

IMD and IML means ‘in mold decoration or labeling’, which is relative new process started from shampoo bottle assembly and have evolved into variety of applications to achieve different outlook. In-mold decoration & labeling (IMD&IML) are surface decorating or labeling process of injection products during the plastic injection molding cycle. A film,pre-printed label or a vacuum formed blister is inserted in the injection mold cavity side and held in place with electrostatic charge, mechanism positioning device, vacuum ports or other methods. Then the mold closed and injected with plastic material, label completely welded into the product surface under injection pressure and temperature. Finally a pick-up robot is used to taken out finished injected part from core side and meanwhile placing an new label to cavity side for next injection. IMD and IML are used on a wide variety of mold types and industries, especially popular with automotive interior, household appliance and digital electrical products ect.

Mold World's engineering team pursue the cutting edge technology of in mold decoration and had accumulated abundant experience with large number of successful cases.

Unscrewing mold with unique demolding mechanism that demolds internal thread or protrusion by opposite direction turning of core ,actuated with hydraulic cylinder , electrical motor or mold opening/closing force,which is the best way to form bottle cap series and small-length tube that are with inner thread and limited space inside. Unscrewing molds are among the relative complex of all injection molds, which requires molder must be with considerable technical savvy and deeply experience to design, fabricate and maintain.In the last decades, a variety of methods for molding and unscrewing the undercut or threaded parts have been developed out and replaced the manual unscrewing operation of mold or low efficient thread machining options.

Common mold methods of unscrewing threads including:
1. Jumping thread. (unscrewing undercut by enforced ejection.).
2. Split tooling. (machining half the thread shape in each half of a split mold).
3. Rotary unscrewing(unscrewing mechanisms are consist of gear system or linkage mechanism actuated by hydraulic cylinder, servo motor or mold opening-closing force.).
4. Collapsible coring.(as showed in introduction of ‘Collapsible Cores Injection Molds’).

The methods above may present challenges to other mold makers but we’ve skillfully the core technical. Our tooling knowledge and experience are always evolving to meet technology development and customer’s needs. we ensure all type of unscrewing toolings work automatically with easily maintenance to increase your production efficiency.

The plastic parts of pipe fitting and elbow shape often need be demolded with arc core-pulling structure mold, also called with arc core-pulling mold. Generally mold consist of crank mechanism or gear system, actuated by angle pin of slider, hydraulic cylinder or motor, some times design the structure in mold with two-stage action sliders when pipe with snap-fit or internal dimples.

For standard pipe fitting and elbow parts(based on EN13480,ASME B31 or other standards ) that are easy purchased from marketing. But many industry products with non-standard pipe or elbow that cannot be replaced with the standards. If it needs big quantity, special material or unique mechanical property request, the best choice is to develop mold(injection or die-casting) for mass production.

In the respect of mold, what challenges tooling manufacturer often meet is arc core-pulling mechanism design that will be directly impact of mold cost, tooling strength, tooling making or project development schedule and subsequent tooling maintenance. Arc core-pulling mechanism normally incorporates critical structures below:
1. Crank mechanism.
2. Four-bar linkage.
3. Two-step action slider designed in mold if pipe or elbow with inner snap-fit,internal dimples or threads. (the 1st step driven by angle pin or hydraulic cylinder, the 2nd step actuated by motor.)
4. Dynamic seal of cooling and oil system design.

Stack mold is more stacks than normal one layer mold and can molding two or multiple layer at one time with same tonnage,same injection pressure. It increases production efficiency and decreases mold cost compared conventional one layer & multiple cavities molds.

Stack Molds is known as multiple-level stack molds, multiple-layer stack molds and contains tandem molds according to mold structure and injection sequence. Both types double the amount of cavities producing parts since a mold is with two or more parting surfaces or mold split lines. A stack mold not requires the bigger injection machine platen size and much more clamping force than a single face mold, because the cavities on both layer is back to back where cancel out each others force. When the stack mold opens, all parting surfaces open simultaneously by means of a mechanical connection system in mold centre,which normally designed with rack and gear system, ball screw system or bar linkage, all three ways actuated by mold open-close force. Some molds are also directly designed with hydraulic push-pull system as actuation.

Tandem mold is a variant of stack molds also called T molds, the difference of tandem mold is while the injection machine opens to demold one parting surface, another parting surface is held together by a locking system, then the parts in both parting surface are injected in alternating cycles to makes the most of machine's capacity.