Core & Cavity Feasibility Study | Mold DFM & Tooling Readiness

PROJECT ID: MM-01-DFM

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The Challenge

4-cavity injection mold for an IP67-rated automotive connector — conformal cooling channels, hot runner system, and Moldflow-optimised gate placement for zero-warp production at 500K+ shot life.

The Solution

Every mold is engineered with conformal cooling channels, optimised gate locations, and balanced runner systems — all simulated in Moldflow before a single piece of steel is cut.

Tooling Readiness & DFM

Mold design analysis

Key Feature

Optimized Cooling Channels

Software

Solidworks, CATIA, Moldflow

Outcome

Full Mold Package + 2D Drawings

Methodology

The Tooling Process

Design Review

Part geometry analysis for DFM — draft angles, wall thickness, parting line feasibility checked upfront.

Mold Design

Core/cavity split, runner layout, gate positioning, and cooling channel routing designed in 3D.

Flow Simulation

Moldflow analysis validates fill pattern, weld lines, sink marks, and cooling uniformity before machining.

Machining & Build

CNC machining, EDM, and surface finish applied to hardened steel tool inserts to final tolerance.

T1 Trial & Sign-off

First-article samples measured against nominal CAD. Iterative adjustments until dimensional sign-off.

Next Phase in Pipeline

Phase 3: Advanced Surface Engineering

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