Customer Requirements
What the customer needed
The customer is a global industrial manufacturing group producing:EV battery tray systemsAutomotive body panelsStructural housing componentsIndustrial machine enclosuresAnnual production:
Case Study
Mold & Die Case Study 15 / 15Large Mold Machining Case Study
Large molds are used to manufacture oversized industrial components requiring extreme structural strength and high dimensional stability.
large mold machining case studymold die cnc machiningcnc machine for mold manufacturing
Project Overview
Standard case data fields.
Industry Automotive / EV / Industrial Manufacturing
Product Large-Scale Mold System
Material P20 / H13 / 1.2738 / 718H / Cast Steel Blocks
Process Heavy CNC Milling + Gantry Machining + EDM + Precision Grinding
Machine Model HYR VMC1165 / Large Gantry CNC Systems
Tolerance +/-0.003-0.008 mm
Surface Finish Project based
Application Automotive Panels / EV Battery Structures / Structural Housing
Challenges
Machining difficulty
Large molds combine:Heavy Structural Engineering+Ultra-Precision Machining+Thermal Deformation Control+Multi-Stage Assembly Accuracy
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 / EV / Industrial Manufacturing Product Large-Scale Mold System Materials P20 / H13 / 1.2738 / 718H / Cast Steel Blocks Process Heavy CNC Milling + Gantry Machining + EDM + Precision Grinding Machine HYR VMC1165 / Large Gantry CNC Systems Tolerance +/-0.003-0.008 mm Mold Weight 1T - 50T+ Application Automotive Panels / EV Battery Structures / Structural Housing
Introduction
Large molds are used to manufacture oversized industrial components requiring extreme structural strength and high dimensional stability.
Unlike standard molds: Small Mold -> Precision Micro SystemLarge Mold -> Structural Manufacturing System They directly determine: Vehicle body structure EV battery housing integrity Industrial equipment shells Aerospace structural parts
What Is A Large Mold?
A large mold is a heavy-duty mold system designed for high-tonnage injection molding or forming of large structural components.
Ultra-Large Mold BaseReinforced Core SystemHeavy Cavity BlocksMulti-Point Ejection SystemHigh-Stiffness Alignment System
High-Tonnage Injection / Forming ForceLarge Material Flow DistributionStructural Cooling & StabilizationLarge Part Formation
Basic structure: During production:
Customer Background
The customer is a global industrial manufacturing group producing: EV battery tray systems Automotive body panels Structural housing components Industrial machine enclosures Annual production: Millions of large structural parts per year Key requirements: Ultra-high rigidity Large-scale dimensional stability Thermal deformation control Long mold life (millions of cycles) High safety factor
Why Large Mold Machining Is Extremely Difficult
Heavy Structural Engineering+Ultra-Precision Machining+Thermal Deformation Control+Multi-Stage Assembly Accuracy
Large molds combine:
Challenge 1
Thermal Deformation in Large Structures Large steel blocks: Expand unevenly Cool inconsistently Warp under machining stress Result: Micron-level deviation becomes millimeter-level error
Challenge 2
High-Weight Structural Stability Mold weight: 1 ton -> 50+ tons Issues: Machine deflection Gravity distortion Fixture instability
Challenge 3
Long Machining Cycle Control Large molds require: 10-30 days continuous machining Multi-stage roughing & finishing Tool wear consistency control Any interruption causes: Re-calibration errors Alignment loss
Challenge 4
Assembly Alignment Precision Large molds require: Multi-section alignment across meter-scale structures Even small misalignment causes: Mold locking failure Injection defects Structural stress concentration
EV Battery Tray Mold
Function: Structural battery enclosure forming
Automotive Body Panel Mold
Function: Door / Hood / Roof panel forming
Industrial Housing Mold
Function: Machine enclosure manufacturing
Aerospace Structural Mold
Function: Lightweight structural component forming
P20 Steel
Advantages: Good MachinabilityCost EfficiencyStable Structure
1.2738 Steel
Advantages: High ToughnessGood Polishing Performance
718H Steel
Advantages: High Hardness Pre-TemperedLarge Mold Stability
H13 Steel
Advantages: Thermal ResistanceHigh Strength
HYR VMC1165 Heavy-Duty System
Best for: Large structural molds EV battery trays Automotive body molds Features: High rigidity bed structure Thermal compensation system Heavy-load spindle stability
Large Gantry CNC Systems
Best for: Ultra-large mold bases Multi-ton structural machining Aerospace-grade molds
Step 1
Large Block Preparation Cast steel / forged blocks Stress pre-relief
Step 2
Heavy Rough Machining Remove: 70-85% Material
Step 3
Thermal Stress Relief Cycles Repeated: Heat treatment Cooling stabilization
Step 4
Semi-Finish Machining Structural shaping Alignment preparation
Step 5
Precision CNC Finishing Requirement: +/-0.003-0.008 mm (structural scale)
Step 6
Deep Hole Drilling & Cooling Channels Used for: Cooling system design Thermal stability control
Step 7
Multi-Section Assembly Alignment Section matching Structural calibration
Step 8
Final Mold Testing High-tonnage injection test Deformation measurement Cooling uniformity validation
Large-Scale CMM Measurement
Ensures: Full structure accuracy Multi-meter alignment
Laser Scanning Inspection
Ensures: Surface deviation mapping Structural integrity
Load Simulation Test
Ensures: Injection pressure resistance Structural safety
Thermal Deformation Test
Ensures: Long-cycle stability
Results
Item
After HYR CNC optimization: Before After Structural Accuracy Medium High Deformation Control Weak Stable Mold Life Standard +40% Assembly Efficiency Low High Defect Rate 3-5% 0.5%
Industrial Impact
They are the physical backbone of modern industry.
Large molds directly support: Electric vehicle industry Aerospace structures Heavy industrial systems Global mass manufacturing
HYR VMC1165
Large EV / automotive molds
Gantry CNC Systems
Ultra-large structural molds
Results
Before and after machining improvement.
| Item | Before | After |
|---|---|---|
| Result 1 | Before optimization | After HYR CNC optimization: |
| Result 2 | Before optimization | Structural Accuracy |
| Result 3 | Before optimization | Medium |
FAQ
Common buyer questions for this case.
What is this mold case about?
This page covers large-scale mold system 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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