MOLD DESIGN & MANUFACTURING

Injection Molds
Precision design · In-house manufacturing integrated delivery

From DFM manufacturability review to mold delivery, we use CAD/CAE full-process digitalization, precision CNC and mirror EDM, and scientific mold-trial verification to provide automotive, electronics, medical, and appliance customers with long-life, high-consistency injection molds.

2006+
Industry Experience
2000+
Cumulative Molds Delivered
±0.005
Machining Accuracy mm
50w+
Shot Life
Get a Mold Quote → Learn About Injection Molding
模具开合 · 充填成型 · 顶出取件（CAD/CAE 数字化开发）
Automotive Manufacturing Electronics & Electrical Appliances Medical Devices Household Appliances Communication Equipment Industrial Components Precision Gears Automotive Manufacturing Electronics & Electrical Appliances Medical Devices Household Appliances Communication Equipment Industrial Components Precision Gears
WHY SENRMOLD

Why Choose Senrui Precision Molds

Keep risk before tooling, keep consistency in mass production—full-process digitalization and precision manufacturing are our core commitment.

DFM Manufacturability Review

Identify draft, wall thickness, sink and assembly risks before mold making; output a review report, significantly reducing later mold-revision cost.

Moldflow mold-flow analysis

Predict fill, pack, warpage, and sink; optimize gate, runner, and cooling layouts; shorten mold-trial cycles.

Precision Machining Equipment

High-precision CNC, mirror EDM, and WEDM wire cutting work together; cavity machining accuracy reaches ±0.005 mm.

Mold Life Assurance

Select optimal mold steel and surface treatment (nitriding/coating); key molds achieve a lifespan of over 500,000 shots.

Fast Mold-Revision Response

Molds are 100% self-designed and manufactured; fast response to design changes, maintenance and mold revisions with a short communication chain.

Integrated Mold & Molding Coordination

Trial and ramp-up done in the same plant; seamless process-data transition reduces outsourcing handover risk.

CORE MOLD CAPABILITY

Core Mold Capabilities

Covers mold-development needs across multi-material, multi-structure, and multi-scenario; fully adapted to scientific molding and high-gloss processes.

Precision Multi-Cavity Mold

High Consistency

High-precision multi-cavity layout and balanced runner design ensure high dimensional consistency per cavity, ideal for scaled mass production.

Production ConsistencyExcellent
Multi-Cavity Balance Interchangeable Assembly
AI Quote Engine
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Two-Shot / Overmolding Mold

Hard-Soft Combination

Dual injection units molding soft-hard combinations and multi-material cosmetic parts simultaneously, reducing assembly steps and improving feel and texture.

Process IntegrationHigh
Multi-Material Assembly Reduction
Mold-Flow Assistance
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High-Gloss / RHCM Mold

Paint-Free

Rapid mold temperature change (rapid heating/cooling) eliminates weld lines and flow marks, achieving a paint-free high-gloss appearance.

Appearance GradeGrade A
Rapid Heating and Cooling Paint-Free
Thermal Simulation
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Insert Molding Mold

Fully Integrated

Metal/electronic inserts are embedded and molded, integrating threads, terminals, and bushings in one piece to reduce post-assembly and connection risks.

Integration LevelHigh
Embedded Insert Integrated
Structural Simulation
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Large Structural-Part Mold

Large Tonnage

For automotive interior/exterior trims and large structural parts, compatible with 650–2000T injection molding machines, supporting multi-component and long glass fiber.

Compatible tonnage2000T
Automotive Large Format
Mold-Flow Assistance
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Thin-Wall High-Speed Mold

High Efficiency

High injection speed fills thin-wall packaging and electronics parts, shortening cycles and lowering per-part cost, with uniform wall thickness and low warpage.

Cycle EfficiencyExcellent
High Speed Low Cost
Cycle Algorithm
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DEV PROCESS

Mold Development Process

A standardized ten-step development chain from requirement to delivery; every step traceable and verifiable.

Requirement Review

Drawing / Sample Confirmation

DFM Analysis

Manufacturability Review

3D Mold Design

CAD Modeling

CNC Machining

Rough / Finish Machining

EDM / Wire Cutting

Mirror / Precision

Heat-Treated Surface

Nitriding / Coating

Grinding & Assembly

Bench Fitting & Tuning

Mold Trial T0/T1

Scientific Mold Trial

Full Dimensional Inspection

CMM Verification

Delivery & Maintenance

Mass-Production Support

EQUIPMENT

Precision Machining & Inspection Equipment

Own high-precision machining and inspection matrix, ensuring mold-cavity accuracy and delivery rhythm.

±0.005mm
CNC Machining Center
High-Rigidity High-Speed Milling
Ra0.1
Mirror EDM
Precision Spark Erosion
±0.003mm
Low-Speed Wire EDM
Ultra-Precision Contour
μclass
CMM Measurement
Full-Dimensional Verification
ΦDeep Hole
Deep-Hole Drilling
Cooling-Water Hole Machining
50–200T
Injection Molding Trial Machine
Same-Plant Mold-Trial Ramp-Up
Equipment CategorySpecification / CapabilityRole in Mold Development
High-Speed CNC Machining CenterMulti-Axis Simultaneous · High RigidityCavity, Slide, Insert Precision Milling
Mirror Spark Machine (EDM)Surface Ra0.1Deep Cavity, Thin Rib & Mirror Finishing
Low-Speed Wire EDMTolerance ±0.003mmPrecision Inserts & Irregular Contours
Coordinate Measuring Machineμm-Level PrecisionFirst Article & Full Mold Dimensional Verification
Deep-Hole Drilling / Heat TreatmentNitriding, Coating Production LineCooling-Water Holes & Surface Strengthening
MOLD STEEL

Common Mold Steels

Select materials sensibly by part material, appearance and life requirements, balancing cost and durability.

View Complete Steel Database
P20
Pre-Hardened 28–35 HRC

General pre-hardened steel with good machinability; suited to volume structural and appearance molds.
718H
Pre-Hardened 33–38 HRC

High polishability; suited to high-gloss and high-appearance molds.
S136
Stainless Steel · Corrosion-Resistant

Corrosion-resistant and highly polishable; suited to medical, transparent, and corrosive-material parts.
H13 / 8407
Hot-Work · High Toughness

Excellent red hardness; suited to long-life and high-mold-temp (RHCM) molds.
NAK80
Mirror · Pre-Hardened

Mirror-grade as delivered, no heat treatment; suited to high-gloss appearance molds.
2344
Hot-Work · Impact-Resistant

Resists thermal fatigue; suited to large, long-cycle mass-production structural molds.
CASE STUDIES

Typical Mold Development Case

Representative mold project types are shown below (examples, not specific customers) to demonstrate multi-industry mold development capability.

Automotive Mold Example

Automotive Grille / Trim Mold

Multi-cavity + slider structure integrates snap-fits and soft-touch surfaces, meeting in-cabin odor and weathering requirements with high mass-production dimensional consistency.

Multi-CavitySliderAutomotive
Electronics Mold Example

Electronics Housing Mold

Thin-wall high-speed + precision inserts, uniform wall thickness and low deformation, with mold-flow analysis optimizing fill and warpage.

Thin-WallPrecisionElectronics
Medical Mold Example

Medical Consumables Mold

S136 corrosion-resistant steel + clean mold trial; key dimensions controlled by CPK, batch traceable, meeting compliance requirements.

Corrosion ResistantCPKMedical
Home Appliance Mold Example

Appliance High-Gloss Mold

RHCM rapid heating/cooling molds eliminate weld lines and flow marks, achieving spray-free high-gloss surfaces and higher cosmetic yield.

RHCM High-GlossSpray-FreeAppliances
0
Years of Industry Experience
0
Cumulative Molds Delivered (Thousand Sets)
0%
On-Time Delivery Rate
0
Key Dimension CPK
CORE METRICS

Core Metrics · Quantified Capability

From design review to delivery support, the accuracy, life, and on-time delivery of mold development are quantifiably traceable. Based on typical project statistics below.

99.5%
Cavity Machining Accuracy Met
Stably controlled within ±0.005mm
96%
Mold Life Achievement Rate
Typically 500K+ Shots
99%
Project On-Time Delivery Rate
Design–Machining–Trial Collaboration
90%
First-Pass Mold-Trial Yield
T0/T1 Scientific Mold Trial
98%
Key dimensions CPK≥1.33
CMM Full-Dimensional Verification
100%

In-House Mold Development Rate

99%

On-Time Delivery Rate

85%

Repeat Customer Rate

Note: The above are typical project statistics ranges. Actual figures vary with mold structure, steel grade, and equipment scheduling; the formal inspection report prevails before delivery.

MOLD SOLUTION COMPARISON

Mold Solution Comparison

Different mold structures involve trade-offs in cost, efficiency, and application scenarios. Click the tags below to match the mold route best suited to your product.

Multi-Cavity vs Single-Cavity Mold

Multi-cavity molds form several parts at once, significantly diluting the per-piece cost; single-cavity molds are more flexible and faster to develop, suited to prototyping and small batches.

Comparison DimensionsMulti-Cavity MoldSingle-Cavity Mold
Unit CostLow (Amortized Tooling)High
Production EfficiencyMulti-Cavity, HighLow
Consistency RequirementBalanced Runner Design: HighAverage
Mold CostHighLow
ApplicationsMedium-to-Large BatchSmall Batch / Prototyping

Two-Shot / Overmolding Mold

Dual injection units or rotary molds simultaneously mold hard-soft combinations and multi-material appearance parts, moving assembly steps into the mold.

Applications

Soft-hard combined handles, keys, seals, two-color appearance parts, automotive interior overmolding.

Key Advantages

Reduce post-assembly, integrate feel and sealing, and improve appearance quality and consistency.

Precautions

Requires dual injection units or rotary mold; material compatibility; more complex runner and rotary-table structure.

Insert Molding Mold

Embed metal parts, electrical terminals, nuts, or bushings into the cavity for one-piece molding, integrating structure and function.

Applications

Electrical terminals, metal nuts/sleeves, sensor brackets, functional parts with metal contacts.

Key Advantages

Integral integration; reduce post-assembly and connection risk; improve connection reliability and efficiency.

Precautions

Insert precise positioning and preheating; prevent flash and bleed; placement tact affects cycle.

High-Gloss / RHCM Mold

Rapid mold temperature variation eliminates weld lines and flow marks, achieving spray-free high-gloss surfaces, demanding high steel and polishing quality.

Applications

High-gloss appearance parts for appliances/automotive interiors, paint-free decorative surfaces, high-consistency housings.

Key Advantages

No weld lines or flow marks, paint-free process savings, and markedly higher appearance yield.

Precautions

Requires mold temperature control system (steam/hot water); slightly longer cycle; steel needs mirror-grade.

Large Structural-Part Mold

For automotive interior/exterior trims and large structural parts, compatible with 650–2000T injection molding machines, supporting multi-component and long glass fiber.

Applications

Automotive grilles/trim, bumpers, large housings, long-glass-fiber reinforced structural parts.

Key Advantages

Large-tonnage adaptability, multi-component integration, high-strength long-glass-fiber molding.

Precautions

Mold lifting and weight management; deformation control; coordination of multi-slides and hot runners.

TRIAL MOLD DEFECT & FIX

Common Mold-Trial Defects & Countermeasures

In the mold trial stage, most issues can be improved from both mold-side and process-side. Below are root causes and countermeasures for common defects.

Mold-Trial DefectsCause (Mold Side)Mold CountermeasuresProcess Countermeasures
Short Shot / Incomplete FillGate/runner too small, insufficient venting, high cavity resistance.Enlarge gate and runner, add venting slotsRaise melt/mold temp; increase injection pressure and speed.
FlashUneven parting line, large insert gaps, mold wear.Re-grind parting surface, fit-grind inserts, repair wearIncrease clamping force, lower melt temperature and injection pressure
Sink MarkUneven wall, gate freezing too early, uneven cooling.Optimize wall thickness, delayed gate, add cooling channelsExtend Holding Pressure, Increase Packing Pressure
WarpageUneven cooling channels, ribs/ejector layoutBalanced cooling, optimize ejection and ribsAdjust process window, change gate position
Drag Mark / StickingInsufficient draft, poor polish, high clamping force.Increase draft, mirror polish, nitride to reduce friction.Lower mold temp, apply release agent, optimize ejection
Ejector Mark / Ejector DamageSmall ejector area, too-fast ejection, high clampingIncrease ejector pins/add ejector pads, reasonable layoutReduce Ejection Speed, Reduce Mold Grip Force
FAQ

FAQ

Questions you may have about mold development cooperation.

How much are mold cost and lead time approximately?+

Cost and lead time depend on product size, structural complexity, number of cavities, and precision requirements. Simple single-cavity molds differ greatly from complex multi-cavity molds; typical mold development cycles are measured in weeks. We provide an online mold quote tool for a quick preliminary estimate; the formal quotation prevails.

What is the minimum order quantity (MOQ)?+

The mold is a one-time investment, with tooling cost incurred at first; the mass-production stage can be scheduled by batch. For prototyping and small batches, we offer small-batch trial-production service; the specific MOQ depends on the product and material—feel free to send us your requirements.

Can you make two-shot, insert, or overmolding (soft-hard combination) molds?+

Yes. We have capabilities in two-shot/overmolding, insert molding, and TPU/TPE soft-hard combination mold development, with dedicated processes such as high-gloss (RHCM) and microcellular foaming to meet appearance and functional integration needs.

How to ensure mold precision and lifespan?+

Cavities are machined collaboratively by high-precision CNC, mirror EDM, and precision wire EDM, achieving accuracy up to ±0.005 mm; preferred mold steel is selected with surface treatments such as nitriding/coating, key molds reaching a shot life of over 500,000 shots, and verified in full dimensions by CMM.

What are the advantages of integral molding?+

Molds are 100% self-designed and self-manufactured; mold trials and ramp-up are done in the same plant, with seamless process-data handover, faster response to mold changes and design revisions, significantly shortening time-to-market and reducing subcontracting interface risk.

How to select mold steel and materials?+

Select material by part material, appearance, and life requirements: P20/718H for general structural parts, 718H/NAK80/S136 for high-gloss and transparent parts, H13/8407/2344 for long life and high mold temperature. We provide a steel database to assist selection and life assessment.

Start Your Mold Development Project

Whether for new-product prototyping, small-batch trial production, or mass production, we provide a complete solution from DFM review and mold development to injection-molding volume production. Send your drawings and requirements to get a dedicated assessment and quotation.

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Focused on precision mold manufacturing and injection molding, integrating design, molding, injection, and assembly, committed to providing high-consistency plastic-part mass-production services to global clients.

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Contact Information

No. 2, Xiangnan 3rd Road, Qiaoli, Changping Town, Dongguan, Guangdong Province
181 1873 7116
senrmold@126.com
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