Customer Requirements
What the customer needed
The customer is a Tier-2 automotive supplier producing:Interior trim systemsExterior plastic partsEV interior modulesLighting housingsAnnual mold production:
Case Study
Mold & Die Case Study 02 / 15Automotive Mold Machining Case Study
An automotive mold is a precision tooling system used to produce vehicle plastic components through high-pressure injection molding.
automotive mold machining case studymold die cnc machiningcnc machine for mold manufacturing
Project Overview
Standard case data fields.
Industry Automotive / Mold & Die
Product Automotive Injection Mold
Material P20 / H13 / NAK80 / S136
Process CNC Milling + EDM + Grinding + Polishing
Machine Model HYR VMC850 / VMC1060 / VMC1165
Tolerance +/-0.005 mm
Surface Finish Ra0.2-0.8
Application Interior Trim / Exterior Parts / EV Components / Functional Plastics
Challenges
Machining difficulty
Automotive molds are not simple tools.They combine:Large Size+Complex Geometry+High Precision+Mass Production Requirements
HYR CNC Solution
Machine configuration
Machine: HYR VMC or gantry CNC system selected according to mold size, steel hardness and accuracy target
Process: Rough machining, stress relief, semi-finishing, EDM support, polishing preparation and inspection
Accuracy Control: Thermal stability, fixture rigidity, finishing allowance control and CMM inspection
Cost Method: Published with existing website assets first to keep implementation cost low
Machining Process
Timeline from raw material to inspection.
01 Material preparation
02 Rough machining
03 Stress relief
04 Finish machining
05 Inspection
Full Case Article
Machining background, difficulty and solution logic.
Quick Facts
Item
Details
Industry Automotive / Mold & Die Product Automotive Injection Mold Materials P20 / H13 / NAK80 / S136 Manufacturing Process CNC Milling + EDM + Grinding + Polishing Machine HYR VMC850 / VMC1060 / VMC1165 Tolerance +/-0.005 mm Surface Finish Ra0.2-0.8 Application Interior Trim / Exterior Parts / EV Components / Functional Plastics
Introduction
Automotive plastic parts are everywhere in modern vehicles.
almost every plastic component starts from a precision mold.
From: Dashboard panels Door trims Air vents Bumpers Lighting housings EV interior modules In automotive manufacturing: Mold QualityPart QualityVehicle AppearanceAssembly Accuracy Therefore: Automotive Mold=Vehicle Manufacturing Foundation
What Is An Automotive Mold?
An automotive mold is a precision tooling system used to produce vehicle plastic components through high-pressure injection molding.
Typical structure: Mold BaseCavity SystemCore SystemCooling ChannelsEjection System After injection: Molten PlasticCoolingSolidificationAutomotive Part
Customer Background
HYR CNC provided a dedicated automotive mold machining solution.
The customer is a Tier-2 automotive supplier producing: Interior trim systems Exterior plastic parts EV interior modules Lighting housings Annual mold production: 200-400 sets Main requirements: Short delivery cycles High repeatability Stable surface quality Multi-cavity efficiency
Why Automotive Mold Machining Is Challenging
Automotive molds are not simple tools.
They combine: Large Size+Complex Geometry+High Precision+Mass Production Requirements
Challenge 1
Large Mold Structures Automotive molds often include: Large CavitiesLarge CoresMulti-Cavity Layouts Problems: Machine travel limitation Thermal deformation Weight-induced deflection
Challenge 2
All cavities must be identical.
Multi-Cavity Consistency For high-volume production: 1 Cavity4 Cavity8 Cavity16 Cavity Even a small deviation causes: Assembly mismatch Product inconsistency Rejection increase
Challenge 3
Automotive parts are highly visible.
Any machining marks will directly affect vehicle aesthetics.
Surface Appearance Requirements Required finishes include: Glossy SurfaceTexture SurfaceHigh-Gloss Interior Finish
Challenge 4
to reduce cycle time.
Cooling Channel Complexity Automotive molds require: Efficient Cooling System Cooling channels are often: Deep Curved Multi-layered
Mold Core
Function: Inner Geometry Formation Requires: High precision Wear resistance
Mold Cavity
Function: Outer Surface Formation Requires: Mirror finish Dimensional stability
Mold Insert
Function: Replaceable Wear Section Advantages: Easy maintenance Cost reduction
Slide Mechanism
Function: Undercut Release System Requires: High precision motion Tight tolerance fit
P20 Steel
Most common automotive mold material.
Advantages: Good MachinabilityStable Performance Applications: General automotive parts
H13 Steel
Advantages: High HardnessThermal Resistance Applications: High-volume molds Durable tooling
NAK80
Advantages: Excellent PolishingStable Surface Finish Applications: Interior automotive parts
S136
Advantages: Corrosion ResistanceMirror Finish Capability Applications: High-end automotive molds Transparent parts
HYR VMC850
Best for: Mold inserts Electrodes Precision cavities
HYR VMC1060
Best for: Medium automotive molds Interior trim molds
HYR VMC1165
Best for: Large automotive molds Multi-cavity molds
Step 1
Material Preparation Forged steel Pre-hardened blocks
Step 2
Rough Machining Remove: 70-85% Material
Step 3
Semi-Finishing Core shaping Cavity profiling Insert preparation
Step 4
EDM Electrode Machining Used for: Deep ribsSharp corners
Step 5
EDM Processing Complex cavities Fine details
Step 6
Finish Machining Requirement: +/-0.005 mmRa0.4
Step 7
Polishing & Texturing Includes: Mirror polishing Texture engraving
Step 8
Mold Assembly Core-cavity fitting Slide system alignment
CMM Inspection
Checks: Geometry accuracy Cavity alignment Multi-cavity consistency
Surface Inspection
Checks: Roughness Polish quality Texture consistency
Mold Trial
Validates: Injection performance Part quality Cycle time
Results
Item
After HYR CNC implementation: Before After Machining Time 100% -28% Accuracy +/-0.015 mm +/-0.005 mm Surface Finish Ra1.6 Ra0.4 Scrap Rate 2.2% 0.25% Mold Life Baseline +30%
HYR VMC850
Electrodes Precision inserts
HYR VMC1060
Automotive molds Medium cavities
HYR VMC1165
Large molds Multi-cavity systems
Related Articles
Injection Mold Machining Case Study Die Casting Mold Machining Case Study Mold Core Machining Case Study Mold Cavity Machining Case Study Automotive CNC Machining Guide
What is an automotive mold?
A precision tool used to produce plastic automotive components via injection molding.
Why is mold accuracy important?
It directly affects vehicle part quality and assembly precision.
What materials are commonly used?
P20, H13, NAK80, and S136.
Why is EDM needed?
To machine deep, sharp or complex cavities that CNC cannot reach.
What is typical tolerance?
Most automotive molds require: +/-0.005 mm
Conclusion
Automotive molds are the backbone of modern vehicle manufacturing.
They require high precision, complex machining strategies and stable production capability.
With advanced CNC systems and mold machining expertise, HYR CNC delivers reliable solutions for global automotive tooling manufacturers.
很好，这一篇开始就进入真正高转化模具 + 压铸 + 新能源汽车核心入口了。 因为： Die Casting MoldEV Battery TrayMotor HousingInverter HousingE-Axle Housing 这些全部都是你前面汽车案例的"订单来源"。
Results
Before and after machining improvement.
| Item | Before | After |
|---|---|---|
| Result 1 | Before optimization | After HYR CNC implementation: |
| Result 2 | Before optimization | Machining Time |
| Result 3 | Before optimization | 100% |
FAQ
Common buyer questions for this case.
What is this mold case about?
This page covers automotive injection mold requirements, machining difficulty, process planning and machine selection.
Which machines are recommended?
HYR VMC850, VMC1060, VMC1165 and gantry CNC systems are selected according to mold size and machining difficulty.
Can HYR-CNC support similar mold projects?
Yes. Send drawings, mold steel, tolerance, surface finish and mold size for a suitable machining proposal.
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