Five cost-reduction design truths of Molds that Subvert Cognition

1. Extreme optimization of compound die structure

Five processes that traditionally need to be completed in steps are integrated into the continuous die:

Punching + flanging compound blade design;

Stretching + shaping is completed simultaneously;

Automatic waste cutting and collection system: The measured single-piece processing time is compressed from 23 seconds to 9 seconds, and the material utilization rate is increased to 92% (the industry average is 78%)

2. "Tian Ji Horse Racing" strategy for material selection

The die base uses ductile iron QT600-3 to replace the traditional Cr12MoV

The key punch uses SKD11 with TD coating (thickness is only 0.03mm)

The unloading plate uses glass fiber-reinforced PEEK material, which directly reduces the cost by 65%, and the mold life is still maintained at more than 300,000 punches

3. Revolution in precision machining

Wire cutting uses a slow wire-cutting process with a precision of 0.01mm; the guide post-hole machining error is controlled at ±0.002mm

The template flatness reaches 0.005mm/m², the measured assembly efficiency is increased by 70%, and the debugging time is shortened by 80%.

4. Dimensionality reduction of modular design

Standardized quick-change punch system; adjustable material guide device

Split demolding mechanism, mold modification cost reduced by 90%, and new product development cycle compressed to 7 days

5. Hidden cost killer: CAE simulation

Through AutoForm analysis, it was found that: adjusting the draw bead height from 1.2mm to 0.8mm;

optimizing the blank holding force from 28T to 19T, reducing material loss by 12%, and reducing equipment tonnage requirements by 30%

Comparison data between traditional design and new design

Indicators                                          Traditional mold                           New design mold

Unit cost                                          USD0.35                                       USD0.21

Debugging time                               48 hours                                           8 hours

Remodeling cost                              USD11500                                       USD850

Customers will not pay for "over-design"

Calculations show that: 20% of mold functions are never used; 35% of processing accuracy exceeds actual requirements; 50% of standard parts have redundant specifications

Development trend of molds in the next three years:

Application of topology optimization technology;

Topology optimization technology automatically calculates the optimal distribution of materials through AI algorithms, helping mold designers reduce redundant structures, improve rigidity and life, and reduce material costs. In the next three years, this technology will accelerate its penetration in the fields of injection molds and stamping molds, especially in the automotive, consumer electronics, and medical device industries.

1 Lightweight design: In automotive injection molds, topology optimization can reduce mold weight by 20%-30%, reduce injection molding machine load, and improve production efficiency. Stamping molds use optimized rib plate structures to enhance deformation resistance and extend mold life.

2 Improve cooling efficiency: Combined with conformal cooling technology, the optimized cooling channel can shorten the injection cycle by more than 15% and reduce warping deformation.

3 Reduce two-way costs: Reduce steel usage and CNC processing time, suitable for large injection molds and precision stamping molds. At the same time, shorten the mold development cycle to adapt to market changes.

Additive Manufacturing (3D Printing) Conformal Cooling Channels;

Additive Manufacturing (AM) technology can manufacture conformal cooling channels that fit the shape of the product and greatly improve cooling uniformity. In the next three years, this technology will become the standard for high-end injection molds.

1 Shorten the injection cycle: Conformal cooling channels can reduce cooling time by 30%-50%, which is suitable for high-demand products such as automotive interior parts and medical thin-walled parts.

2 Improve product quality: Reduce shrinkage marks and warping, and improve the yield of optical-grade injection molded parts (such as lenses and light guide plates).

3 Reduce energy consumption: A more efficient cooling system reduces the energy consumption of injection molding machines, which is in line with the trend of green manufacturing.

AI-driven mold DFM (Design for Manufacturability) system

Industry challenges and AI solutions

Traditional mold design relies on the experience of engineers and is prone to manufacturability (DFM) problems, resulting in many mold trials and high costs. The AI-driven DFM system automatically optimizes mold structure, gate location, and ejection scheme through machine learning analysis of historical data to reduce design errors.

1 Intelligent gate design: AI can automatically recommend the best gate location to reduce weld marks and is suitable for multi-cavity injection molds.

2 Automatic defect prediction: Early warning of problems such as shrinkage marks and pores to optimize the design of automobile bumper molds and electronic housing molds.

3 Fast quotation and simulation: Combined with CAE simulation (such as Moldflow), AI can generate mold cost estimates in minutes to accelerate customer decision-making.