products optimization, Tooling Design & Engineering Support

GPMFG provides complete mold support for micro to large-scale production, including 2D and 3D design for optimal manufacturing, and a range of single/multi-component molds.

Top engineering design team - more experienced & more professional

The GPMFG mold design team consists of 10 designers with a minimum of 15 years of experience in mold design and actual manufacturing molding with excellent CAD/CAM/CAE skills. Evaluate your drawings and provide engineering guidance to help you design moldable parts optimized for manufacturing. From tooling design concepts to process development and validation, we ensure that every aspect of production meets the ultimate goal of producing high quality parts.

Design Assistance

GPMFG boasts excellent mold design proficiency, employing a comprehensive and mature design process encompassing part analysis (DFM), mold flow analysis, structural analysis, and process analysis. Utilizing software such as Unigraphics, Pro-E, and CAD enhances our design precision.

Design For Manufacturability (DFM)

GPMFG offers you a valuable tool, Design for Manufacturing (DFM), to cut down on tooling expenses and expedite the manufacturing process. This essential step involves factoring in manufacturing considerations during the design phase, pinpointing and resolving potential issues.

Basic Information

Cavities
Using Material
Shrinkage
Part size & weight analysis
Mold steels
Moldbase steel and spec
Injection machine size

Sink mark analysis
Draft analysis
Engraving and Aspect spec
parting line analysis
Insert line analysis
Slide and retractor lines
Ejector line
Gate location and size
Layout

Mold structure

Mold Flow Analysis For Mold & Tooling Design

Mold flow analysis, a computer-aided engineering (CAE) tool, allows you to simulate molten plastic behavior during injection molding. This aids in optimizing mold design, preventing issues like warpage, shrinkage, and short shots.

Our Mold Flow Analysis offers crucial data on injection molding stages (filling, holding, and cooling). Anticipating potential problems before mold construction empowers you to make informed decisions about mold and tooling design.

Benefits of Mold Flow Analysis include reduced development time, enhanced product quality, increased productivity, and cost reduction. By optimizing pre-production mold and tooling designs, it helps you steer clear of expensive and time-consuming rework or modifications.

Mold manufacturing design process

Part Design: Begin by designing the part you want to mold, considering its shape, size, and material. Ensure manufacturability, avoiding overly small or complex features that may pose molding challenges.

Mold Design: After finalizing the part design, create a 3D model for the mold cavity and core. Consider factors like molten plastic flow, part cooling, and ejection from the mold.

Mold Manufacturing: Once the 3D CAD design is ready, manufacture the mold using materials like steel or aluminum. Utilize various processes such as CNC machining, EDM, and casting.

Mold Testing: Thoroughly test the manufactured mold to confirm proper functionality, assessing molten plastic flow, part cooling, and successful ejection.

Production: Upon successful testing and approval of the mold, commence production. The output rate per hour depends on part size and complexity, as well as the capabilities of the injection molding machine.

Some additional considerations that need to be taken into account during the mould design process:

Mold Steel Selection: Your choice of materials significantly impacts the strength, durability, and overall cost of the mold.

Parting Line: Deliberate on the parting line’s location, where the mold halves meet; it plays a crucial role in the smooth ejection of molded parts.

Draft: Ensure the application of proper draft angles to the walls of the molded part for easy ejection from the mold.

Cooling System: The efficiency of the cooling system directly influences the cycle time of the injection molding process.

Cost: Factor in the mold cost, as it directly contributes to the overall expenses of the injection molding process.

Free DFM Report

Get Engineer Assistance

We use the latest engineering software to build 2D or 3D mold structures and simulate them to prove that they are correct and capable.

Molding analysis ensures successful mold design

GPMFG’s engineers employ finite element analysis software to simulate the behavior of molten polymers during complex injection molding processes. By analyzing the collected data, we can predict and identify potential molding issues, providing guidance to optimize designs.

1. The analysis of flow:

Predicting filling delays, hits, and balance
Analyzing mating lines, pack wind positions, and glue feeding
Determining injection pressure and closing force requirements

2. Flow channel balance analysis:

Balancing flow channel systems in multi-cavity mold cavities or families Recommending flow channel sizes and quantities for achieving flow balance

3. Gate position analysis:

Analyzing the best gate location for optimal mold flow
Automatically analyzing the position of additional gates

4. Cooling analysis:

Assessing the mold's cooling water layout
Identifying areas that require stronger cooling
Predicting molding cycle and evaluating product thickness

5. Warpage analysis:

Predicting product deformation and shrinkage values in X and Y directions
Adjusting water inlet/pressure holding parameters to reduce mold deformation

6. Shrinkage analysis:

Analyzing molding shrinkage with put number and volume
Assessing the presence of shrinkage marks

7. Gas-assisted analysis:

Predicting gas-assisted molding shrinkage and deformation
Evaluating gas penetration distance, effect, and optimal location

8. Core transfer analysis:

Predicting mold core shift trend and correcting mold design
Reducing the weak impact strength of core during filling

9. Stress analysis:

Predicting residual stress distribution and size in molded products

10. Fiber orientation analysis:

Controlling the fiber orientation of plastic, injection molded parts
Simulating percentage simulations according to different fibers
Improving material properties such as bending and tensile strength

11. Overmolding analysis:

Analyzing flow, warpage, and bonding in two-color molding

12. Microchip encapsulation analysis:

Predicting chip encapsulation, flow, and curing conditions in mold cavity
Assessing the effect of flow on gold wires and pins

13. Bottom fill analysis:

Optimizing thermoset molding conditions and fill dispensing model simulation
Predicting various forms and injection pressure/clamping force requirements

14. Birefringence prediction:

Adjusting gate position, process conditions, or modifying product structure to achieve low residual stress
Predicting the occurrence and severity of asymmetric birefringence in optical parts.

Gallery of Molds

FAQs for Injection Molding

What information should be provided to obtain the quotation?

Formal product 3D drawing

Formal product 2D drawing with Tolerance

Parts mateirla

Molds Cavity number if exporting molds

Injection point type if exporting molds

Molds cavity steel if exporting molds

Molds frame steel if exporting molds

Molds life if exporting molds，shot

What’s the process for injection mold making?

In order to meet the requirements of customers, GP MFG designs molds and manufacturing processes through analysis and strict molding process, to ensure the perfect increase in the production of molds.

Step 1: Provide DFM report and mold flow analysis report for customer confirmation

Step 2: Provide design mold drawings for customer confirmation

Step 3: Provide reconfirmation of the drawing after modification of the mold design

Step 4: After the drawing is confirmed Ok, start to arrange the mold manufacturing

Step 5: Provide weekly tooling progress report

Step 6: Send out T1 sample until the mold is confirmed Ok

Can you customize the mold according to my sample?

Yes.

If accurate product drawing is available,attach 2D product drawing with tolerance and 3D product drawing.
If you have accurate sample, if there are no drawings or only sketches, please provide the final sample,we will arrange to make a DFM report to send to you for confirmation, and then design the mold.

How much does a mold cost？

The cost of the mold is affected by the size and material of the product,the complexity of the structure and the quantity of production,and the surface requirements, and so on.Because of the great difference,the price of the mold can not be estimated.If you want to know the cost of mold precision,please send email to us.

How long does it take to make a mold?

It depends on the complexity of the product structure,the specific delivery time will be indicated on the quotation sheet.The following delivery dates are for reference:

20-30 days for molds less than 1 ton

30-45 days for molds from 1 ton to 3 tons

45-60 days for molds from 3 ton to 5tons

How long is the mold life? How to protect?

In the mold industry,the life grade of the mold is divided into:100 thousand times,300 thousand times,500 thousand times and 1 million times.The die life is related to the die steel,which is selected according to the plastic material,the surface treatment of the parts and the potential production quantity.

Mold exported to customers in your country or region,in the correct use of die mold and regular maintenance,the service life of the actual can completely meet the design service life,a failure if the life of the mold in a reasonable period,our project engineer will evaluate the replacement parts or mold repair solution,will arrange manufacture and send again.

Jacob Deng

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Files

Available files are PDF, DWG, STL, STEP, IGES. The maximum supported file size is 100MB. For large or multiple files please place into one folder and compress into a ZIP or RAR file, or send an email with attachments to jacob@gainpower-mfg.com