Rapid Tooling for Industrial Equipment Enclosure Large-Size Mold Delivered with Precision and Speed
A manufacturer of industrial control systems required a large injection mold for ABS equipment enclosures. The housing measured 480mm * 360mm and required high structural rigidity.
Due to increasing demand, the client needed a backup mold within 4 weeks to avoid production delays.
- Large cavity size
- Risk of warpage
- Thick-to-thin wall transition areas
- Mold weight over 3 tons
- Required 10,000 validation parts
Large molds usually require extended machining cycles and multiple fitting adjustments.
- Rough machining on large gantry CNC
- Fine machining on precision 5-axis centers
- Independent processing of slider systems
- Pre-assembly tolerance simulation
Cooling channel layout was optimized to ensure uniform shrinkage. Structural reinforcement ribs were fine-tuned during DFM review.
Our rapid tooling team worked in three shifts to compress production time.
The mold was delivered in 26 days.
Achievements include:
- Warpage controlled within 0.3mm
- Assembly fit rate above 99%
- 10,500 test parts produced successfully
- No secondary modification required
The client integrated the backup mold into their production line, increasing output capacity by 45%.
This project demonstrates that rapid tooling is not limited to small components. Even large industrial molds can be delivered quickly through strategic engineering and process optimization.
