Injection Mold Design & Manufacturing
End-to-end mold engineering: from Moldflow-validated design to hardened multi-cavity production tools. Aluminum soft tooling in 2-3 weeks for market validation, P20/H13/S136 production molds in 4-6 weeks — with in-house molding trials and CMM-verified T1 samples before anything ships.
Free Consultation2-3 Weeks
Soft Tooling
4-6 Weeks
Production Mold
1 - 16+
Cavity Count
Up to 1M+ Shots
Mold Life
Materials
| Grade | Properties | Typical Applications |
|---|---|---|
| P20 Steel (Pre-hardened, 28-32 HRC) | Good machinability, uniform hardness, no heat treatment distortion risk, polishable to SPI B-1 | Volume production molds up to 500,000 shots, general consumer and industrial parts |
| H13 Steel (Hardened, 48-52 HRC) | Excellent heat and wear resistance, high toughness, suitable for glass-filled resins | Long-life molds 500,000-1,000,000+ shots, abrasive materials, high-temperature engineering resins |
| S136 Stainless (Hardened, 48-52 HRC) | Superior corrosion resistance, mirror polishability to SPI A-1, excellent for optical surfaces | Optical parts, medical devices, transparent PC/PMMA parts, corrosive resins (PVC, POM) |
| 718H / NAK80 (Pre-hardened, 37-43 HRC) | Higher hardness than P20 without heat treatment, excellent texturing and polishing response | Cosmetic-critical parts, textured surfaces, mid-to-high volume programs |
| Aluminum 7075 (Soft Tooling) | Machines 4x faster than steel, excellent thermal conductivity for shorter cycles, economical | Prototype molds, bridge tooling, market validation runs of 25-25,000 shots |
| Beryllium Copper (Inserts) | Thermal conductivity 3-4x tool steel, eliminates hot spots in deep cores and thin ribs | Cooling-critical inserts, deep bosses, areas prone to sink marks and warpage |
Process Parameters
| Parameter | Standard Range |
|---|---|
| Mold Classes | SPI Class 101 (1M+ cycles) to Class 104 (prototype) |
| Cavity Count | 1 - 16+ cavities (balanced runner) |
| Soft Tooling Lead Time | 2 - 3 weeks (aluminum, T1 samples included) |
| Production Mold Lead Time | 4 - 6 weeks (P20/H13/S136, T1 samples included) |
| Max Mold Size | 1200mm x 1000mm (fits up to 1,000-ton presses) |
| Cavity/Core Tolerance | ±0.01mm (machining), ±0.005mm (EDM/grinding) |
| Part Tolerance Baseline | ±0.05mm (tighter achievable per resin and geometry) |
| Mold Flow Analysis | Moldflow simulation included on every project |
| Runner Systems | Cold runner, insulated |
| Mold Base Standards | DME, HASCO, LKM, FUTABA per customer region |
Surface Finishes
SPI Polish (A-1 to D-3)
Full SPI standard range: A-1 mirror finish (Ra ≤ 0.012μm) for optical parts through D-3 dry blast matte. Polish grade specified per surface in the mold design review, matched to part cosmetic requirements.
Texture (VDI 3400 / Mold-Tech)
EDM texture per VDI 3400 scale or chemical etch per Mold-Tech standards. Textures hide weld lines and witness marks, improve grip, and mask minor cosmetic defects in production.
EDM Finish
Non-directional spark-eroded finish for cavities, ribs, and features tools cannot reach. Controlled VDI grades from near-polish to coarse texture, uniform across complex geometry.
Nitriding / Cavity Hardening
Surface hardening to 65+ HRC for glass-filled and abrasive resins. Extends mold life 2-3x in high-wear gate and shut-off areas without through-hardening distortion.
Chrome / Nickel Plating
Hard chrome plating for wear surfaces and corrosion protection with PVC and flame-retardant resins. Electroless nickel for complex geometry with uniform coverage.
Laser Engraving
Cavity identification, date codes, recycling symbols, and customer part numbers engraved per specification. Interchangeable date insert systems available.
Design for Manufacturing (DFM)
- Run Moldflow analysis before cutting steel: gate location, fill balance, weld lines, and cooling are validated on screen first
- Select mold steel by lifetime volume: P20 to 500K shots, H13 beyond, S136 for optical/corrosive — do not overpay for steel you will not use
- Design balanced cooling channels within 1.5-2x diameter from cavity surfaces for cycle time and dimensional stability
- Maintain uniform part wall thickness (±25%) to prevent sink marks, voids, and warpage
- Apply minimum 1° draft per side, 1.5° per 0.025mm of texture depth on textured surfaces
- Confirm ejection strategy early: ejector pin marks, stripper plates, or air poppets per cosmetic requirements
- Position gates to fill thick-to-thin, keep weld lines out of cosmetic and load-bearing zones
- Radius all internal corners minimum 0.5mm to reduce stress concentration and improve steel life
- Standardize mold bases (DME/HASCO/LKM) for economical spare parts and maintenance in your region
- Upload STEP/IGES files for a free DFM report within 24 hours covering gate strategy, cooling layout, and steel selection
Tooling & Capacity
| Type | Lead Time | Suitable For |
|---|---|---|
| Aluminum Soft Tool | 2-3 weeks | 25 - 25,000 shots, prototypes, bridge production, market validation before steel investment |
| P20 Production Mold | 4-5 weeks | 50,000 - 500,000 shots, general consumer and industrial parts, cost-effective volume tooling |
| H13 / S136 Hardened Mold | 5-6 weeks | 500,000 - 1,000,000+ shots, abrasive/corrosive resins, optical surfaces, maximum tool life |
| Multi-Cavity Mold | 5-6 weeks | High-volume programs, 2-16+ cavities, lowest per-part cost |
Quality Assurance
- Incoming steel verification with mill certificates and hardness testing for every mold base and insert
- In-process CMM inspection of cores and cavities before assembly — errors caught before fitting, not after
- Electrode and EDM dimensional verification for critical features and shut-off surfaces
- Cooling channel pressure testing and flow verification before mold trial
- T1 mold trial on in-house presses with full process documentation (temperatures, pressures, cycle time)
- First-article CMM inspection of T1 samples against 3D model with full dimensional report
- Mold fit and function checklist: ejection, slides, lifters, venting, and interlocks verified before shipment
- Trial process parameters documented and shipped with the mold for fast startup in your facility
- Spare parts list with standardized components (DME/HASCO/LKM) for regional availability
- Quality system documented and controlled; mold warranty terms defined in every contract
Applications
- New product development: production molds engineered from your CAD with Moldflow validation
- Export molds: tools built to run in your facility, with your press specs, standards, and language documentation
- Replacement and duplicate tooling: reverse-engineered or rebuilt from existing molds and samples
- Multi-cavity scaling: proven single-cavity designs scaled to 4-16 cavities for volume production
- Insert and overmolding tools: metal inserts, two-shot, and soft-grip overmolding
- Bridge tooling: aluminum molds delivering parts in 2-3 weeks while production steel is built
- Medical and optical tooling: S136 mirror-polish cavities for transparent and cleanroom parts
Why Choose FHY Precision
Moldflow simulation included on every project — fill, cooling, and warpage validated before steel is cut
In-house mold trial: T1 samples molded and CMM-verified on our presses before the mold ships
Full steel range: P20, 718H, NAK80, H13, S136 matched to your volume and resin — no overpaying
Aluminum soft tooling from 2-3 weeks: validate your market with real molded parts before steel investment
Export mold experience: DME/HASCO/LKM standards, press-spec matching, and English documentation
Integrated molding factory: your mold is proven in production conditions, not just tried once
quality system documented and controlled with steel certs, hardness reports, and full dimensional documentation
Free DFM report within 24 hours: gate strategy, cooling layout, steel selection, and cost optimization
FAQ
1. What is the minimum order quantity (MOQ) for injection molding?
Our standard injection molding MOQ is 100 pieces. With aluminum soft tooling, MOQ is as low as 25 pieces — ideal for market validation and pre-production runs. If you only need the mold built for running in your own facility (export mold), there is no molding MOQ at all.
2. How long does injection mold manufacturing take?
Aluminum soft tooling: 2-3 weeks including T1 samples. P20 production molds: 4-5 weeks. H13/S136 hardened molds: 5-6 weeks. Multi-cavity molds: 5-6 weeks. Every quote includes a confirmed T1 sample date, and our free DFM review is completed within 24 hours of receiving your CAD files.
3. What is the difference between steel and aluminum molds? Which should I choose?
Aluminum molds cost 30-50% of steel, are ready in 2-3 weeks, and last around 25,000 shots — ideal for prototypes, market validation, and bridge production. Steel molds (P20/H13/S136) take 4-6 weeks and deliver 500,000-1,000,000+ shots — the right choice for confirmed volume production above 10,000 pieces. Many customers start with aluminum to validate the design, then scale to steel; FHY builds both in-house.
4. How much does an injection mold cost? Can I get a rough estimate?
Indicative pricing (USD, EXW): simple single-cavity P20 mold: $2,000-$5,000. Multi-cavity mold (2-8 cavities, P20/H13): $5,000-$20,000. Complex high-precision mold (S136): $20,000-$60,000+. Aluminum soft mold: $800-$3,000. Final cost depends on cavity count, steel grade, and surface finish. Send your drawings for a firm quote within 24 hours.
5. Do you provide mold flow analysis?
Yes — Moldflow simulation is included on every project at no extra cost. We simulate fill pattern, gate balance, weld line and air trap locations, packing, cooling efficiency, and warpage before cutting steel. Catching a gate location problem on screen costs nothing; fixing it in hardened steel costs thousands. The simulation report is shared with you during design review.
6. What resins can your molds run?
We design molds for ABS, PC, PC/ABS, PP, PE, PA6/PA66 (including glass-filled), POM, PMMA, TPU, TPE, and engineering blends. Steel selection follows the resin: H13 or nitrided cavities for glass-filled grades, S136 stainless for PVC/POM and optical PC/PMMA, standard P20 for unfilled commodity resins. Resin-specific shrinkage rates are applied in cavity sizing.
7. Do you provide free DFM analysis before tooling?
Yes. Upload your STEP/IGES file and we return a free DFM report within 24 hours covering wall thickness uniformity, draft angles, gate strategy, cooling layout, ejection plan, steel selection, and manufacturability risks. This review happens before quotation so the price you receive reflects a design that will actually mold well.
8. What CAD file formats do you accept?
We accept STEP (.stp/.step), IGES (.igs), Parasolid (.x_t), SolidWorks (.sldprt), STL, DXF, DWG, and PDF drawings. For mold design, 3D STEP models are the preferred master definition. From physical samples only, we offer reverse engineering to create production-ready CAD before mold design begins.
9. Can you build export molds to run in my own facility?
Yes — export molds are a core business. We build to your press specifications (tie bar spacing, ejector pattern, locating ring, nozzle radius), use your preferred mold base standard (DME for North America, HASCO for Europe, LKM/FUTABA for Asia), and ship with English documentation: assembly drawings, spare parts list, trial process parameters, and maintenance guide. T1 samples and trial video are provided before shipment.
10. Can I get samples before approving the mold?
Yes. Every mold is trialed on our in-house presses (T1 trial), and first-article samples are CMM-verified against your 3D model with a full dimensional report. You approve samples before the mold ships or before production begins. If adjustments are needed, T2/T3 trials follow — mold acceptance criteria are agreed in the contract.
11. Do you offer third-party inspection (SGS / Bureau Veritas)?
Yes. On request we can arrange independent third-party inspection by SGS or Bureau Veritas at any stage - before shipment, during production, or on incoming material. You receive a full independent inspection report (dimensional CMM measurement, material verification, and appearance/surface check) so parts are verified by a neutral party before leaving our facility.
12. How do you ensure mold quality during manufacturing?
Quality gates at every stage: incoming steel verification with mill certs and hardness testing, in-process CMM inspection of cores and cavities before assembly, electrode verification for EDM features, cooling channel pressure testing, and a documented T1 trial with CMM-verified first articles. Problems are caught at the machining stage — not discovered at trial.
13. Do you sign NDA before reviewing design files?
Yes, we sign NDA before quotation, not just before production. Molds embody your product IP — CAD files, specifications, and program information are treated as confidential assets. We serve clients in medical, consumer electronics, and automotive sectors where IP protection is critical. NDA signing is our standard practice.
14. How is the mold shipped and what export packaging do you use?
Molds are cleaned, rust-protected, and sealed before packing in IPPC-certified wooden crates with moisture barriers. Shipment includes assembly drawings, spare parts list, trial parameters, and maintenance documentation. We ship worldwide via sea freight (3-5 weeks to US/Europe) or air freight for urgent programs. Photos and trial video are provided before dispatch.
15. What common injection molding defects does good mold design prevent?
Our Moldflow-validated design process prevents the major defects: Short shots → gate size and fill pressure optimized in simulation. Flash → proper shut-off design and adequate press tonnage matching. Sink marks → uniform wall design flagged in DFM. Warpage → balanced cooling simulated before steel cutting. Weld lines → gate location moved so lines fall in non-critical zones. Each risk is addressed on screen, where changes are free.
16. Can you also run production after building the mold?
Yes. As an integrated molding factory, we offer complete tooling + production programs: your mold is maintained under a shot-count program, stored in controlled conditions, and production runs ship with full inspection reports. One purchase order covers mold, molding, surface finishing, and light assembly — or take the mold to your facility anytime; you own it either way.