Customer Requirements
What the customer needed
The customer manufactures:Automotive plastic componentsConsumer electronics housingsIndustrial plastic productsAnnual mold production:300+Sets
Case Study
Mold & Die Case Study 01 / 15Injection Mold Machining Case Study
Injection molding is one of the most widely used manufacturing processes in the world.
injection mold machining case studymold die cnc machiningcnc machine for mold manufacturing
Project Overview
Standard case data fields.
Industry Mold & Die
Product Plastic Injection Mold
Material P20 / H13 / NAK80 / S136
Process CNC Milling + Drilling + EDM + Polishing
Machine Model HYR VMC850 / VMC1060 / VMC1165
Tolerance +/-0.005 mm
Surface Finish Ra0.2-0.8
Application Automotive / Medical / Electronics / Consumer Products
Challenges
Machining difficulty
Injection molds combine:Large Material Removal+High Precision+Complex Geometry+Mirror Surface RequirementsMold accuracy directly affects product dimensions, appearance and assembly quality.
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 Mold & Die Product Plastic Injection Mold Materials P20 / H13 / NAK80 / S136 Manufacturing Process CNC Milling + Drilling + EDM + Polishing Machine HYR VMC850 / VMC1060 / VMC1165 Tolerance +/-0.005 mm Surface Finish Ra0.2-0.8 Application Automotive / Medical / Electronics / Consumer Products
Introduction
Injection molding is one of the most widely used manufacturing processes in the world.
almost every plastic component begins with a mold.
From: Automotive interior parts Electronic housings Medical products Household appliances Packaging products The quality of the mold directly determines: Part AccuracySurface QualityProduction EfficiencyTool Life For this reason: Injection Mold=Manufacturing Foundation
What Is An Injection Mold?
An injection mold is a precision tool used to form plastic products through molten material injection.
Typical structure: Mold BaseCavityCoreCooling SystemEjection System After the mold closes: Plastic InjectionCoolingPart FormationEjection A high-quality mold ensures: Stable dimensions Excellent appearance Long service life
Customer Background
HYR CNC provided a complete mold machining solution.
The customer manufactures: Automotive plastic components Consumer electronics housings Industrial plastic products Annual mold production: 300+Sets Challenges: Tight delivery schedules Mold accuracy requirements Surface finish consistency Electrode machining efficiency
Why Injection Mold Machining Is Difficult
Injection molds combine: Large Material Removal+High Precision+Complex Geometry+Mirror Surface Requirements
Challenge 1
requiring advanced CNC machining strategies.
Complex Mold Cavities Many products contain: Deep RibsThin WallsComplex Surfaces
Challenge 2
This increases machining difficulty.
High Hardness Tool Steel Common mold steels: P20H13NAK80S136 After heat treatment: 30 HRC52 HRC
Challenge 3
Any machining marks affect final product quality.
Surface Finish Requirements Consumer products often require: Polished SurfaceMirror FinishTexture Surface
Challenge 4
Dimensional Accuracy Small mold errors may cause: FlashShrinkage IssuesAssembly Problems
Mold Core
Function: Internal Product Geometry Requirements: Precision machining High wear resistance
Mold Cavity
Function: External Product Shape Requirements: Excellent finish Dimensional stability
Mold Insert
Function: Replaceable Wear Area Benefits: Lower maintenance cost Easier repair
Slider And Lifter
Function: Undercut Release Requirements: High precision fit
P20 Steel
Advantages: Good MachinabilityCost Effective Applications: General plastic molds
NAK80
Advantages: Excellent PolishabilityStable Performance Applications: Cosmetic product molds Transparent product molds
S136
Advantages: Corrosion ResistanceMirror Finish Capability Applications: Medical molds Optical molds
H13
Advantages: Heat ResistanceWear Resistance Applications: High-production molds
HYR VMC850
Suitable for: Mold inserts Electrodes Small precision molds Advantages: High spindle speed Excellent finishing capability
HYR VMC1060
Suitable for: Medium injection molds Automotive molds Advantages: Balanced rigidity and efficiency
HYR VMC1165
Suitable for: Large mold bases Multi-cavity molds Advantages: Large travel Heavy cutting capability
Step 1
Material Preparation Use: Pre-hardened steel Forged steel blocks
Step 2
Rough Milling Remove: 70%85%Material Create: Main cavity Structural features
Step 3
Semi-Finishing Machine: Core surfaces Cavity surfaces Insert pockets
Step 4
for EDM operations.
Electrode Machining Produce: Copper ElectrodesGraphite Electrodes
Step 5
Finish Machining Requirements: Tolerance+/-0.005 mmRa0.4
Step 6
EDM Processing Machine: Deep ribs Sharp corners Fine details
Step 7
Polishing Possible finish: SPI-A1Mirror Finish
Step 8
Assembly And Inspection Verify: Core-cavity fit Sliding components Cooling channels
CMM Inspection
Verify: Geometry Position accuracy Dimensional consistency
Hardness Testing
Verify: Heat treatment quality
Surface Roughness Testing
Requirement: Ra0.2-0.8
Mold Trial Inspection
Verify: Product quality Mold function Cycle time
Results
Item
After implementing HYR CNC machining solutions: Before After Machining Time 100% -30% Mold Accuracy +/-0.015 mm +/-0.005 mm Surface Finish Ra1.6 Ra0.4 Scrap Rate 2.0% 0.2% Mold Life Baseline +25% Customer benefits: Faster mold delivery Better product quality Lower maintenance cost Higher production efficiency
HYR VMC850
Electrodes and precision inserts.
HYR VMC1060
General injection molds.
HYR VMC1165
Large molds and mold bases.
Related Articles
Mold Core Machining Case Study Mold Cavity Machining Case Study Mold Base Machining Case Study Automotive Mold Machining Case Study Medical Mold Machining Case Study
What is an injection mold?
An injection mold is a precision tool used to produce plastic parts through the injection molding process.
What materials are commonly used?
P20, H13, NAK80 and S136 are widely used.
Why is mold accuracy important?
Mold accuracy directly affects product dimensions, appearance and assembly quality.
Why is polishing required?
Polishing improves surface quality and part appearance.
What tolerance is typical?
or better.
Most precision injection molds require: +/-0.005 mm
Conclusion
Injection molds are the foundation of modern plastic manufacturing.
Their complex geometries, demanding surface requirements and strict dimensional tolerances require advanced CNC machining solutions.
With reliable machining performance, high precision and extensive mold manufacturing experience, HYR CNC provides efficient injection mold machining solutions for customers worldwide.
Results
Before and after machining improvement.
| Item | Before | After |
|---|---|---|
| Result 1 | Before optimization | After implementing HYR CNC machining solutions: |
| 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 plastic 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.
Recommended Machines
Similar Case Studies
More Mold & Die machining proof.
Automotive Mold Machining Case Study
An automotive mold is a precision tooling system used to produce vehicle plastic components through high-pressure injection molding.
Die Casting Mold Machining Case Study
Die casting is one of the most important manufacturing processes in modern automotive and electric vehicle production.
Mold Core Machining Case Study
The mold core is one of the most critical components in injection molds and die casting molds.
Mold SEO Cluster
Related mold manufacturing resources.
Automatic internal links connect this case study with the Mold & Die hub, related case studies and core technical articles.
Hub Page
Mold Die Manufacturing
Mold manufacturing, CNC machining services and precision mold company topic hub.
Related Case StudyAutomotive Mold Machining Case Study
An automotive mold is a precision tooling system used to produce vehicle plastic components through high-pressure injection molding.
Related Case StudyDie Casting Mold Machining Case Study
Die casting is one of the most important manufacturing processes in modern automotive and electric vehicle production.
Request Quote
Need a similar CNC machining solution?
Send your drawing, material, tolerance, surface finish and production volume. HYR-CNC will recommend the right machine configuration and machining proposal.
Start Machine SelectionRelated Links