Process: 3D parting design, Standard mold base selection (DME/HASCO), Conformal cooling channel optimization

Accuracy: ±0.005mm for critical mating surfaces

Validation: FEA structural strength verification

Equipment: 5-axis CNC (DMG MORI, ±0.005mm accuracy)

Material: Tool steels (NAK80/S136/H13)

Process: Roughing (0.3mm stock) → Semi-finishing (0.1mm) → Finishing

Surface Finish: Ra≤0.4μm after finishing

Purpose: EDM for complex cavities/fine textures

Equipment: High-speed engraving machine (±0.003mm)

Electrode Wear: ≤0.1% per discharge

Key Parameter: Electrode scaling 0.05-0.15mm (spark gap compensation)

Equipment: Mirror EDM (Sodick AG60L, Ra≤0.1μm)

Parameters: Pulse width 2-100μs, current 1-50A

Applications: Deep slots/narrow gaps/surface textures

Equipment: Slow wire-cut EDM (±0.003mm)

Wire Diameter: Φ0.02-0.3mm (brass/coated)

Applications: Precision inserts/special-shaped holes

Dimensional: CMM (±0.002mm, ISO 2768)

Surface: White light interferometer (Ra≤0.1μm)

Material: Spectrometer for alloy verification

Key Steps: Core/cavity alignment (gap≤0.01mm), Ejection system smoothness test (≤5N resistance), Cooling system pressure test (0.5MPa/30min)

Tools: Laser interferometer for alignment

Validation: Process stability (pressure/temp variation ≤2%), Dimensional yield (CPK≥1.67), Surface quality (no flow marks/sinks)

Equipment: Injection press (50-3000T clamping force)