Customer Requirements
What the customer needed
The customer is a global consumer goods manufacturer producing:Medical disposable productsPackaging containersElectronic accessory partsDaily-use plastic componentsAnnual production:
Case Study
Mold & Die Case Study 14 / 15Multi-Cavity Mold Machining Case Study
Multi-cavity molds are designed to produce multiple identical parts in a single injection cycle.
multi-cavity mold machining case studymold die cnc machiningcnc machine for mold manufacturing
Project Overview
Standard case data fields.
Industry Injection Mold / High-Volume Manufacturing
Product Multi-Cavity Mold
Material S136 / NAK80 / P20 / H13 / High-Polish Steel
Process CNC High-Speed Milling + EDM + Micro Polishing + Thermal Control
Machine Model HYR VMC850 / VMC1060 / VMC1165
Tolerance +/-0.002-0.005 mm
Surface Finish Project based
Application Packaging / Medical / Consumer Electronics / Daily Products
Challenges
Machining difficulty
Multi-cavity systems are not just "duplicated molds".They require:Perfect Symmetry+Flow Balance Engineering+Micro-Consistency Control+Thermal Stability Management
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 Injection Mold / High-Volume Manufacturing Product Multi-Cavity Mold Materials S136 / NAK80 / P20 / H13 / High-Polish Steel Process CNC High-Speed Milling + EDM + Micro Polishing + Thermal Control Machine HYR VMC850 / VMC1060 / VMC1165 Tolerance +/-0.002-0.005 mm Cavity Range 2-128 Cavities Application Packaging / Medical / Consumer Electronics / Daily Products
Introduction
Multi-cavity molds are designed to produce multiple identical parts in a single injection cycle.
This is the foundation of high-volume industrial production.
Instead of producing one part per shot: Single-Cavity Mold -> 1 Part / CycleMulti-Cavity Mold -> 8 / 16 / 32 / 64+ Parts / Cycle
What Is A Multi-Cavity Mold?
A multi-cavity mold is an injection mold system containing multiple identical cavities that produce the same part simultaneously.
Mold BaseHot Runner SystemMulti-Branch Flow ChannelsMultiple Identical CavitiesSynchronized Ejection System
Single Injection CycleMaterial Distributed to All CavitiesSimultaneous Part FormationMass Output Per Cycle
Basic structure: During production:
Customer Background
The customer is a global consumer goods manufacturer producing: Medical disposable products Packaging containers Electronic accessory parts Daily-use plastic components Annual production: 5 Billion+ plastic parts per year Key requirements: Extremely high productivity Perfect cavity consistency Stable flow balance Zero cavity variation Low per-unit cost
Why Multi-Cavity Mold Machining Is Difficult
Multi-cavity systems are not just "duplicated molds".
Perfect Symmetry+Flow Balance Engineering+Micro-Consistency Control+Thermal Stability Management
They require:
Challenge 1
Cavity-to-Cavity Consistency All cavities must be identical: +/-0.002-0.005 mm variation maximum Even tiny differences cause: Weight imbalance Shrinkage variation Product rejection
Challenge 2
Flow Balance Control Molten material must distribute evenly: Equal Pressure Across All Cavities Problems if not balanced: Short shots Overfill in some cavities Dimensional instability
Challenge 3
Thermal Distribution Stability Temperature must remain uniform: Hot runner balance Cooling channel symmetry Otherwise: Uneven shrinkage Warping defects
Challenge 4
High-Speed Wear Synchronization All cavities wear differently if not perfectly aligned: Early failure of specific cavities Maintenance imbalance Production inconsistency
Medical Multi-Cavity Mold
Function: Syringes / Caps / Disposable Components Cavities: 32-128 cavities
Packaging Mold
Function: Bottles / Caps / Containers Cavities: 16-96 cavities
Consumer Electronics Mold
Function: Small plastic housings / accessories Cavities: 8-64 cavities
Industrial Component Mold
Function: Mechanical small parts Cavities: 4-32 cavities
S136 Steel
Advantages: High Precision StabilityMirror Polish CapabilityCorrosion Resistance
NAK80
Advantages: Excellent Surface FinishStable Machining Behavior
P20 Steel
Advantages: Cost EffectiveGood Structural Stability
H13 Steel
Advantages: Thermal ResistanceHigh Strength
HYR VMC850 Ultra Precision
Best for: Micro cavity machining High precision insert work Medical multi-cavity molds
HYR VMC1060
Best for: Medium cavity systems Packaging molds Electronics molds
HYR VMC1165
Best for: Large multi-cavity systems High-output industrial molds
Step 1
Material Preparation High-grade steel blocks Pre-stress relieved materials
Step 2
Rough Machining Remove: 60-75% Material
Step 3
Thermal Stress Relief Reduce: Internal deformation risk Machining distortion
Step 4
Precision CNC Finishing Requirement: +/-0.002-0.005 mm consistency
Step 5
Cavity Duplication Calibration Ensures: Identical geometry Symmetry control
Step 6
Flow Channel Optimization Hot runner balance tuning Pressure equalization
Step 7
Assembly Testing Full cavity synchronization Injection test validation
CMM Multi-Cavity Inspection
Ensures: Each cavity identical Position accuracy
Flow Simulation Test
Ensures: Balanced injection flow
Weight Consistency Test
Ensures: Product weight uniformity
Thermal Balance Test
Ensures: Stable cooling behavior
Results
Item
After HYR CNC optimization: Before After Cavity Consistency Medium High Production Efficiency Standard +45% Scrap Rate 3.0% 0.3% Cycle Stability Medium High Cost per Part High -30%
Industrial Impact
They are the foundation of modern high-volume manufacturing.
Multi-cavity molds directly enable: Mass production economies Low-cost consumer goods Medical disposable scaling Global supply chain efficiency
HYR VMC850
Medical & micro multi-cavity molds
HYR VMC1060
Packaging & electronics molds
HYR VMC1165
Large industrial multi-cavity systems
Related Articles
Medical Mold Machining Case Study Optical Mold Machining Case Study Hot Runner Mold Case Study Progressive Die Case Study Die Insert Machining Case Study
What is a multi-cavity mold?
A mold that produces multiple identical parts in a single cycle.
Why is it important?
It drastically reduces production cost per part.
What is the main challenge?
Ensuring perfect cavity consistency and flow balance.
How many cavities are common?
From 2 to over 128 depending on product type.
Conclusion
Multi-cavity molds are the core of high-volume manufacturing systems.
They require extreme precision, perfect symmetry, and advanced flow control engineering.
With high-end CNC machining and system-level manufacturing capability, HYR CNC delivers stable and efficient multi-cavity mold solutions for global industries.
Results
Before and after machining improvement.
| Item | Before | After |
|---|---|---|
| Result 1 | Before optimization | After HYR CNC optimization: |
| Result 2 | Before optimization | Cavity Consistency |
| Result 3 | Before optimization | Medium |
FAQ
Common buyer questions for this case.
What is this mold case about?
This page covers multi-cavity 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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