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- DFM (Design for Manufacturability)
- Mold Flow Analysis
- Detailed Mold Design
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Engineers review the part design, plan the mold layout (gating, cooling, ejection), and create detailed 2D/3D drawings. This is the most critical stage.
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- Cutting
- Milling
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Large blocks of steel (mold base, core, cavity) are cut to size and then rough-machined to remove the bulk of the material, getting close to the final shape.
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3. Precision Machining
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- CNC Machining
- EDM (Electrical Discharge Machining)
- Wire-Cut EDM
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The mold's features are finished to high accuracy. CNC creates the general shape. EDM is used for deep, sharp corners and complex geometries that CNC cannot reach.
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4. Finishing & Fitting
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- Grinding/Polishing
- Bench Work
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Surfaces are polished to the required finish (textured, polished, etc.). Components like ejector pins, sliders, and lifters are fitted and adjusted by skilled mold makers.
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- Hardening
- Tempering
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The core and cavity are heat-treated to achieve the required hardness and wear resistance, essential for a long mold life. This step is sometimes done earlier.
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6. Quality Inspection
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- CMM (Coordinate Measuring Machine)
- Visual Inspection
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All critical dimensions are meticulously checked against the CAD model to ensure they are within tolerance.
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7. Mold Trial (Trial Run)
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- Assembly on Press
- Sample Shots
- Adjustments
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The mold is assembled and tested on an injection molding machine. Initial parts are made and measured. The mold and process parameters are adjusted until the parts meet specifications.
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8. Final Approval & Completion
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- Part Approval
- Delivery
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After sample parts are approved by the customer, the mold is finalized, documented, and delivered for production.
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