What Are the Advantages of Mold Design and Manufacturing？

The advantages of custom molds and tailored designs for those molds are numerous. Although there are many factors that affect the quality of custom molds, you will be able to reap multiple benefits by reaching out to an industry leader that employs quality resins for the injection molding process, and adheres to the important components in the process of injection molding.

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However, the process of custom injection molding begins with exactly what you think it begins with – customized mold design and development. Custom molds stand out as the best option because they’re manufactured to fit your specific needs and industry requirements, among other things.

What are the 3 biggest benefits of custom mold designs?

Injection molding is a manufacturing process that provides an impressive number of advantages across many different industries, one of the biggest ones being customizable mold design. There are three main advantages to custom molds:

1. Virtually limitless possibilities – The word “custom” says it all. Injection molding has been used to manufacture anything, ranging from mechanical components to medical devices. Depending on your needs, you can acquire any kind of mold necessary for your manufacturing process, making it faster and more efficient. 
2. Reduced number of errors – While there is, unfortunately, always a chance for manufacturing errors to occur, custom molds can lower their frequency immensely. By designing a custom mold you are able to significantly improve the consistency of your product, thus lowering potential errors. 
3. Faster production pace – Finally, custom molds enable manufacturers to eliminate any guesswork from the production process and create more products in less time. It is through the design of custom molds that this kind of effect is achieved. 

Are there more advantages to custom mold designs?

In addition to the mentioned advantages, custom injection molding, whether ceramic or plastic, brings additional benefits that can help boost your business. By incorporating a custom mold design, you may also expect:

1. Accuracy – Since the possibilities when designing a custom mold are almost endless, you can be certain that even the molds for the most complex of products are going to be designed with the maximum accuracy.
2. Automation – Since custom molds allow for fewer number of errors during the manufacturing process, and since their design is such that it’s easy to arrive at the end product, you can automate even more aspects of the process, leading to reduced costs.
3. Costs – Speaking of reducing costs, it is the quickened production pace that reserves higher revenue streams for your business, since you’ll be producing more products in the same amount of time, while cutting costs with a more automated process.
4. Materials – Finally, custom mold designs take into account the materials you’re planning on using for the end product. This means that the mold is designed to maximize all of the characteristics of the material we use while manufacturing the product, making the end result as good as it can be. 

If you need custom molds, why not work with a renowned custom injection molding company?

Here at Wunder-Mold, we’re proud of our 25-year long career in the custom injection molding industry. We have the experience, expertise, and enthusiasm required to provide you with exactly what your business needs. 

1. Efficient high production

Once you have developed the molds, the process is extremely fast with cycle times as short as 10 seconds. It is excellent for medium and high-volume production runs for anything from 10,000 parts to well over 100,000 depending on what molds you use. 

Sometimes you can increase production by using a multi cavity or family mold, where several parts are produced from one press to further increase the manufacturing rate.

If you are outsourcing your molding then it’s also important to consider an efficient front-end design and order process – take a look at our on demand manufacturing.

4. Large material choice

There is a huge range of plastic materials that you can select from depending on what properties you need from your final part. And you are not limited to plastic, Protolabs also offers liquid silicone rubber molding. 

You can even use fillers in the molding material, which adds greater strength to the completed part, and you have a huge range of colors to choose from as well.  Talk to us about what you need your part to achieve – there are generally a number of different options.

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1. Initial cost

If you are committing to steel mold tools for high production volumes (100,000+) then it can take a great deal of time and machining to produce and this can be a significant capital cost. If you need lower volumes of parts then this will affect your cost per part price and it may be worth exploring other options such as using aluminum molds instead.

2. Initial lead times

It can take up to 12 weeks to produce steel tooling. If you need to get production running before this then take a look at our on-demand production; by using aluminum molds and digitizing our front-end process we can ship anything from 25 to 10,000+ parts in 15 working days or less from the point that you first upload your CAD. Sometimes parts shipped in as little as one day.

For very low production runs there are other technologies such as 3D printing or CNC machining which could provide a more cost-effective answer more quickly.

3. Design limitations

You will need to consider certain design elements, such as:

• Using draft and radii to help ejection of the parts
• Avoiding undercuts and sharp edges
• Controlling wall thicknesses

You also need to consider where to place your gates, ejectors and cooling lines if aesthetics are important. And remember it’s also hard to change the design of a mold – you can remove part of the mold, or add plastic to your final part, but not the other way round.

For smaller production runs, 3D printing allows you to design virtually any shape or geometry that you require. As a rapidly developing technology there is an increasing number of plastic and other materials, even metal, that we can produce. 

4. Small part runs are not always cost effective

Most people think that they should only turn to injection molding for orders of 100,000+ parts; but there are other options when you can use this process for smaller production runs.

Using more affordable aluminium molds and quick turnaround times (as fast as a day) our on-demand service helps keep your per part cost down. It is ideal for anything between 10,000 and 25,000 parts, but can help control costs for production runs even smaller than this.

For low production runs measured in the hundreds or less then it is also worth exploring other manufacturing technologies such as 3D printing and CNC machining. With these technologies the cost per part will be lower and you will not face the initial set up costs or lead times involved in producing molds.

If you want to learn more, please visit our website Mold Design and Manufacturing.