The tool shop is the reason we can commit to housing geometry that other factories decline: straight walls without draft, fine textures on tall parts, and parting lines that stay invisible after millions of shots. Design and machining are done by our own team, so a change agreed with the customer becomes a machining instruction the same week.
From drawing to first article
- DFM review. Wall thickness, rib and boss proportions, draft where it is allowed, gate position and the surface requirement are reviewed together with the customer.
- Mold design. Cavity count, runner layout, cooling circuit, ejection and any slide or lifter are documented in 2D and 3D for approval.
- Machining. CNC, EDM, wire EDM, milling, grinding and drilling are carried out on site. All mold-shop machines were installed new.
- Fitting and trial. The tool is fitted, spotted and trialled in one of the production machines, with first-article parts measured in the laboratory.
- Approval and hand-over. Samples, measurement reports and the process sheet go to the customer; the tool is released to production after approval.
Mold shop equipment
| Machine | Quantity |
|---|---|
| CNC machining center | 2 |
| EDM (die-sinking) | 4 |
| Wire EDM | 4 |
| Milling machine | 8 |
| Surface grinder | 5 |
| Drilling machine | 3 |
Capacity and team
We build 25 to 35 new molds per month. The mold shop is staffed by 20 mold makers; mold design is carried out by three designers within the 13-person engineering department. Multi-cavity tools are routine: the stress-mark solution described in our engineering notes was production-proven on a 1×8 cavity tool.
New tools and tool transfers
We build new tools from a 3D model and we also take over existing tools from another supplier: the mold is measured, the cooling and ejection are reviewed, and the tool is refurbished before it goes into our machines. Both routes end with the same first-article approval and a written process sheet.
