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- The mold inserts operated continuously for over 1 million molding cycles under a 340°C high-temperature working condition, with no dimensional drift.
- Product flash defects were reduced by 98%.
- The solution successfully passed all testing items, and the customer has extended the application of this solution to its other factories worldwide.
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- The mold inserts operated continuously for over 1 million molding cycles under a 340°C high-temperature working condition, with no dimensional drift.
- Product flash defects were reduced by 98%.
- The solution successfully passed all testing items, and the customer has extended the application of this solution to its other factories worldwide.
Get a Quote
Customer Type
Global leading Tier-1 suppliers in the automotive and consumer electronics connector industries, including Yazaki, TE Connectivity, Sumitomo Electric, and other industry leaders.
Pain Points
hermal Fatigue
Connector molds need to adapt to high-temperature engineering plastics (such as LCP and PPS). The injection temperature exceeds 340°C, and conventional mold steels are prone to thermal fatigue wear and dimensional drift.
Pain Points 1
Insert Deformation
Products feature complex thin-wall structures. Slender inserts are prone to deflection and deformation under high-temperature and high-pressure conditions, resulting in flash defects and excessive hole position concentricity deviation.
Pain Points 2
Flow Balance
For multi-cavity molds (typically 64 cavities or more), runner balance is extremely difficult to control. Uneven product weight among cavities directly affects terminal retention force and electrical performance.
Pain Points 3
Standard Compliance
Customers must pass automotive performance standards such as USCAR-20, with extremely strict requirements for mold lifespan and process stability.
Pain Points 4
Corrosion-Resistant Steel
Core inserts are all made of imported 1.2083 (ESR) high corrosion-resistant mirror-finish mold steel. Through precise vacuum hardening, the hardness is accurately controlled at HRC 52, ensuring excellent wear resistance and dimensional stability in high-temperature acidic environments.
Geometric Interlocking
Slender PIN inserts adopt a multi-sided insert positioning design. The geometric interlocking structure significantly enhances the lateral pressure resistance of thin-wall inserts, completely eliminating injection-induced displacement and ensuring precise hole position concentricity.
Balanced Gating System
A multi-point gating and hot runner balancing technology is applied, combined with precise temperature control for each cavity through mold temperature controllers. Based on iterative optimization with Moldflow simulation analysis, weld lines and air traps are completely eliminated, achieving cavity filling weight variation ≤ 0.5%.
Results / Outcomes
The optimized mold solution achieved exceptional performance in high-temperature, high-precision production environments. It delivered long-term dimensional stability, significantly reduced product defects, and successfully passed all validation tests.
The mold inserts operated continuously for over 1 million molding cycles under 340°C high-temperature conditions, with no dimensional drift.
1 Million+ Cycles
Product flash defects were reduced by 98%.
98% Reduction
The solution successfully passed all testing programs, and the customer has expanded its application to other factories worldwide.
Global Deployment
Capabilities Demonstrated
Precision Machining of High-Hardness Materials
Specialized in the complete machining process of high corrosion-resistant and high-hardness mold steels, including turning, milling, grinding, PG machining, and precision wire EDM.
Engineering-Level Mold Optimization Capability
Based on customers’ injection molding conditions, we provide comprehensive engineering solutions covering material selection, insert structure optimization, and runner balancing.
High-Consistency Mass Production Assurance
Through precision fixtures, internally developed multi-stage core processes, and 100% inspection, we ensure micron-level interchangeability for multi-cavity molds with up to 128 cavities.
Automotive Standard Compliance Experience
With deep knowledge of connector industry testing standards such as USCAR and LV214, we proactively support customers in completing required validation processes.
