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Rapid Injection Tooling & Molding
We completed a set of rapid tools for a tail light project for our customer within 30 days, which included over 30 components. Our team worked tirelessly to help the customer meet the testing timeline.
How do we shorter the manufacturing time?
1. Fully understanding the project
2. Choosing the right material
3. Optimize the mold design
4. Using stock mold base
- Fully understanding the project
As a rule of thumb, thoroughly understanding the project from the outset can save significant time by minimizing the need for frequent back-and-forth with the customer. For this project, we quickly mastered the requirements, completing the mold design and analysis within a week - a process that typically takes a month for traditional mold-making companies. Meanwhile, we ordered all necessary materials so that we could begin work as soon as we received the customer’s approval.
- Choosing the right material
The choice of material for each tool (whether aluminum or steel) depends on the type of molding we are producing. Our engineers are experienced in selecting the appropriate material for each component. Identifying components suitable for aluminum molds is especially beneficial, as these can be produced in a shorter timeframe.
For mass production molds, the mold cavity is typically made in one piece to ensure a mold life of 100K to 1M shots. However, since this was a low-volume prototype mold project, we needed to strike the right balance between quality and speed.
- Optimize the mold design
After analyzing the design, we decided to split some of the cavities. For example, the mold core for the reflectors could have been made as a single piece, but this would have been complex and time-consuming to mill using a 5-axis machine. By splitting it into several pieces, we were able to use two or three machines, reducing the production time by more than half without compromising quality.
Other key decisions were made to achieve the optimal balance between cost and quality. For instance, by using hand-load inserts, we avoided the need for a more complex mold with lifters and sliders. Considering the volume of the moldings and the cycle time for loading and unloading the inserts, this approach proved to be more cost-effective.
- Using stock mold base
Additionally, all mold cavities were designed based on our stock mold base, which meant we didn’t need to spend time and money ordering new ones. This helped shorten the lead time and saved costs, enabling us to meet our customer’s budget.
Our previous experience with similar projects also guided certain decisions. For instance, the outer lens of a tail light typically requires 2K (two-shot) molding — red for the brake light and white for the reverse — and this project was no different. Unfortunately, 2K molds are often expensive to produce.
However, for quantities of 200-300 sets, we can save costs by creating a transparent molding and then partially painting or tinting it as needed.
In the end, we completed the project within the specified deadline, allowing our customer to test the lights on a prototype car without waiting eight months for mass production molds. This also gave them the opportunity to modify and improve parts of the design.
1. Fully understanding the project
2. Choosing the right material
3. Optimize the mold design
4. Using stock mold base
- Fully understanding the project
As a rule of thumb, thoroughly understanding the project from the outset can save significant time by minimizing the need for frequent back-and-forth with the customer. For this project, we quickly mastered the requirements, completing the mold design and analysis within a week - a process that typically takes a month for traditional mold-making companies. Meanwhile, we ordered all necessary materials so that we could begin work as soon as we received the customer’s approval.
- Choosing the right material
The choice of material for each tool (whether aluminum or steel) depends on the type of molding we are producing. Our engineers are experienced in selecting the appropriate material for each component. Identifying components suitable for aluminum molds is especially beneficial, as these can be produced in a shorter timeframe.
For mass production molds, the mold cavity is typically made in one piece to ensure a mold life of 100K to 1M shots. However, since this was a low-volume prototype mold project, we needed to strike the right balance between quality and speed.
- Optimize the mold design
After analyzing the design, we decided to split some of the cavities. For example, the mold core for the reflectors could have been made as a single piece, but this would have been complex and time-consuming to mill using a 5-axis machine. By splitting it into several pieces, we were able to use two or three machines, reducing the production time by more than half without compromising quality.
Other key decisions were made to achieve the optimal balance between cost and quality. For instance, by using hand-load inserts, we avoided the need for a more complex mold with lifters and sliders. Considering the volume of the moldings and the cycle time for loading and unloading the inserts, this approach proved to be more cost-effective.
- Using stock mold base
Additionally, all mold cavities were designed based on our stock mold base, which meant we didn’t need to spend time and money ordering new ones. This helped shorten the lead time and saved costs, enabling us to meet our customer’s budget.
Our previous experience with similar projects also guided certain decisions. For instance, the outer lens of a tail light typically requires 2K (two-shot) molding — red for the brake light and white for the reverse — and this project was no different. Unfortunately, 2K molds are often expensive to produce.
However, for quantities of 200-300 sets, we can save costs by creating a transparent molding and then partially painting or tinting it as needed.
In the end, we completed the project within the specified deadline, allowing our customer to test the lights on a prototype car without waiting eight months for mass production molds. This also gave them the opportunity to modify and improve parts of the design.