Home / Mold Development

Mold Development Services

Tooling solutions include injection/die-casting/stamping mold design and manufacturing. Using S136 tool steel and hot runner systems, we achieve ±0.005mm accuracy and 100,000+ cycles. Accelerate pilot runs for automotive, electronics, and medical components.

Get an Instant Quote

All uploads are secure and confidential.

Capabilities

Our Process

Case Studies

Resources

Get In Touch

Core Manufacturing Process

001

Mold Design

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

002

CNC Cavity Machining

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

003

Copper Electrode Machining

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)

004

Electrical Discharge Machining (EDM)

Equipment: Mirror EDM (Sodick AG60L, Ra≤0.1μm)
Parameters: Pulse width 2-100μs, current 1-50A
Applications: Deep slots/narrow gaps/surface textures

005

Wire-Cut EDM

Equipment: Slow wire-cut EDM (±0.003mm)
Wire Diameter: Φ0.02-0.3mm (brass/coated)
Applications: Precision inserts/special-shaped holes

006

Inspection

Dimensional: CMM (±0.002mm, ISO 2768)
Surface: White light interferometer (Ra≤0.1μm)
Material: Spectrometer for alloy verification

007

Mold Assembly

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

008

Trial Molding

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)

New Product Development Process

Design for Manufacturing. From Concept to Mass Production.

Concept

(Product Definition Consultancy)

Product Requirements Document

Concept Prototype

Risk Assessment

EVT

(Engineering Verification Test)

Design Goals & Specifications

Engineering Prototypes

lssue Tracking & Resolution

DVT

(Design Verification Test)

Product Requirements Document

Design Verification Testing

Design Finalization

PVT

(Production Verification Test)

Mold Development

QA Engineering

Regulatory Certification

Pilot Production

MP

(Mass Production)

PMC , QC

Supply Chain Management

Production Management

Engineering Challenges in Mold Development

Dimensional Drift Over Time

Surface Quality Instability

Mold Wear and Unexpected Failure

Get an Instant Quote

Global Recognition & Regulatory Compliance

We combine award-winning industrial design expertise with rigorous global regulatory compliance, empowering your products to access global markets and earn industry recognition seamlessly.

Global Design Awards & Honors

Global Certification

Explore Our Full Credentials icon_arrow_next

Why Our Mold Development Approach Is Different

Design-Driven Tooling Strategy

Tooling is developed during the product engineering phase, allowing for earlier risk detection, fewer redesigns, and faster project timelines.
Precision-Oriented Manufacturing

Mold components are produced under strict dimensional control, ensuring high repeatability, stable geometry, and reduced post-processing requirements.
Lifecycle-Focused Engineering

Molds are engineered not just for initial production but for long-term reliability, including maintenance accessibility, wear prediction, and tool longevity planning.
Integrated Production Support

We provide continuous support through the entire production cycle, ensuring that molds perform consistently and meet evolving production needs.

Build Precision Tooling That Performs Over Time

Engineered molds designed for accuracy, durability, and scalable manufacturing.

Get an Instant Quote

Precision mold architecture improves product consistency.
Thermal balance engineering enhances dimensional stability.
Simulation-driven tooling reduces trial risk.
Durable mold systems support long-term production efficiency.

Mold Development Workflow

STEP.01

Mold Design Engineering

Product geometry is translated into tooling structure.

Mold feasibility validation
Architecture modeling
Motion mechanism definition

STEP.02

Simulation & Optimization

Digital validation reduces physical trial risk.

Flow simulation
Cooling performance modeling
Structural stress analysis

STEP.03

Precision Mold Fabrication

Tool components are manufactured under controlled tolerances.

CNC precision machining
EDM processing
Surface finishing

STEP.04

Mold Assembly & Fitting

All mold components are assembled and fine-tuned.

Mechanical alignment
Clearance optimization
Functional verification

STEP.05

Mold Trial & Validation

Initial molding trials validate tool performance.

Sample part evaluation
Dimensional validation
Defect analysis

Successful Cases

Al Interactive Companions

DingTalk AI Recorder

Consumer Electronics

HHO GPods headphones

Smart Home & Appliances

Honeywell Air Purifier

Explore Our Full Case icon_arrow_next

Trusted by Leading Businesses

TESTIMONIAL 1

As our reliable long-term engineering partner, they provide precise customized mold solutions with strict tolerance control. Each optimized mold scheme effectively reduces molding defects and ensures stable high-yield mass production.

TESTIMONIAL 2

Their comprehensive mold development expertise has greatly elevated our overall manufacturing capability. With meticulous precision control and full-cycle technical support, they consistently deliver stable molding quality and efficient mass production for our hardware products.

TESTIMONIAL 3

Relying on profound engineering experience in mold development, the team provides highly adaptable customized mold schemes. Their professional optimization ensures excellent dimensional accuracy and long service life of molds in continuous high-volume production.

Get an Instant Quote

Engineering Insights & Resources

LKK Design: Your Partner Across Every Product Stage

Product development is not a linear process. Different challenges emerge at different stages — from early concept validation to engineering execution and large-scale manufacturing. LKK Design provides targeted support at each stage, helping teams move forward with clarity, efficiency, and confidence.

Precision EDM for Mold Development

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)

Get an Instant Quote

Got Questions?

Q.
What does your mold development service include?

Our full-cycle mold development covers mold structure design, 3D modeling, mold flow analysis, mold opening, sample trial, debugging optimization, and mass production technical support.
Q.
What types of molds can you develop?

We specialize in precision injection molds for plastic parts, including small precision components, large structural parts, multi-cavity molds, and complex appearance molds for consumer hardware.
Q.
What is the general mold development cycle?

The development timeline varies by mold complexity, part size and structural difficulty. Standard precision molds are completed within 3–5 weeks from design to qualified sample delivery.
Q.
Do you provide mold flow analysis before mold opening?

Yes. We conduct comprehensive mold flow simulation analysis in advance to predict potential defects such as warpage, shrinkage and weld marks, and optimize mold structure in advance.
Q.
Will you provide sample testing and debugging after mold opening?

We offer multiple rounds of mold trial, sample verification, parameter adjustment and structural optimization until the finished parts meet dimensional and appearance quality standards.