Injection Mold Machining
As we know, quality molds are related to professional mold design, high precision processing machines, rich experiences assembling moldworkers, and team management. We produce our mold on industry-leading CNC and EDM equipment with standard accuracies of +/- 0.005” on the mold, then hand bench for superior surface finish.
We are truly a full-service, mold building resource. With 8 CNC Wire and Die Sink EDM machining centers available, along with 4 high precision 5-axis CNC Milling Machines—we have all the resources needed to efficiently, accurately and effectively manage multiple tool builds at a time. Our latest AG Charmilles Cut 2000S Wire EDM is Capable of precision as fine as .000040”, with finishes as fine as .80RA, while our Sodick 650L CNC Mill is capable of .000050” precision with surface finish as fine as 1nm.
If your project is demanding and requires extremely high precision and accuracy, Contact Us. Discover the benefit of working with a true full-service, engineering driven company.
The Injection Mold Making Process
01. High Speed CNC Machining
One of the major advantages of 5-axis milling is that it allows us to produce highly complex parts using only one tool, which reduces human involvement while ensuring that the parts are processed with repeatable precision and shorter turnaround times. Our high-speed 5-axis milling capability underpins the delivery of superior plastic products, making your mold precise and efficient.
Our five-axis CNC machining enables angular tolerances of two thousandths of a degree (0.002°). It can help us easily complete the CNC machining of the mold profile, and the accuracy can reach 0.00005mm.
We have vertical milling centers throughout for a variety of applications from roughing, finish milling, and electrode manufacturing. Finish milling is done on Makino and Sodick machines, hard milling steel to 62HRC, This is accurate and repeatable to within .0001mm.
02. Electrode Making
We use high speed CNC machines for electrode fabrication because they are linear motor driven and accurate/repeatable to within 0.0001 mm, which guarantees the accuracy of the electrodes. We will also perform CMM inspection on the key dimensions of the electrode to obtain the accuracy of the mold.
03. Sinker EDM
Our team of highly skilled engineers have a deep understanding of sinker EDM machining and how it can be used to produce precise mold with tight tolerances.
Sinker EDM is commonly used to process complex profiles machining that CNC milling can't for any conductive material tool steel, including exotic and precious metals. As sinker EDM uses electrical discharge to corrode the profile into the work piece, hardened alloys won't see heat distortion as with traditional machining methods. it can help improve mold accyracy.
Our work pieces with a minimum part feature of .01mm, an accuracy of ±.0005mm and a repeatability of ±.00005mm.
04. Wire EDM
Benefits of Wire EDM Cutting
Wire EDM lends itself to some of the closest and precision machining tolerances available. Our experienced EDM machinists have years of experience. setting up, programming and finishing EDM work from start to completion.
Our wire EDM machines that are linear-motor-driven for accuracy and repeatability to within .00004” along with very high reliability. We commonly use Ø.004” wire for day-to-day tight tolerance, high volume components with the ability to run Ø.002″ wire for specific applications.
Wire EDM services offer additional benefits like:
  • Superior Consistency - The wire cutter recycles the new wire during operation to produce consistent electrode quality, which avoids the problem of inaccurate workpiece quality due to wire loss and helps maintain repeatable accuracy to ensure consistent results.
  • Simultaneous Cutting - When the same OEM inserts components need to be machining at the same time, the EDM line can cut stacked sheeting, which can increase productivity and save you time and money.
  • Material Compatibility - Wire cut discharge machining allows precise cutting on a wider range of materials, including conventional iron, copper, etc. Because there is no contact between the workpiece and the wire, the cutting process can accurately process extremely thin materials with tungsten carbide (such as tungsten carbide) or softer materials (such as copper). This effectively eliminates the distortion caused by stress in the cutting.
  • Eliminates Finishing - Wire cutting EDMs can produce fine finishing, and the work coming out of our wire cutters is almost ready, with no additional surface treatment required.
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05. Inspection
We performs inspection of critical dimension for mold core and inserts using CMM (Coordinate Measuring Machine) using CMM Manager Inspection Software. All inspection equipment is continuously calibrated and traceable.
06. Polishing / Precision Grinding
Hand grinding and mirror polishing are the processes of finishing metal surfaces using canvas, stones and abrasive paste, as well as specialized instruments. To get high-performance polishing results, great polishing ability and high artistic vision are required.
Our skilled and experienced polishing operators and capable of producing up to SPI A-1 #3 Diamond Buff finish. can meeting from electronic, automotive to optics mold requirement.
07. Mold Assembly & Samples
Our mold engineers add fits and gaps during the design process to ensure the interchangeability of the insert parts of the mold. For each mold, the designers are able to provide a fully detailed comprehensive inspection of the machining process documentation.
Injection Mold Machining FAQs

How does sinker EDM work?

Sinker EDM is a precision machining process that removes metal material from the mold through discharge corrosion to form a specific set shape. Here’s how it works:

1. Electrode installation and centering
First, install the electrode onto the Sinker EDM machine. The electrode is usually a tool made of graphite or copper that can be CNC machined into a special shape and is used to discharge the mold during the machining process. Next, the electrode is centered to ensure its accurate position during machining. The centering process typically involves using the machine’s measurement system to determine the correct position and angle of the electrodes.

2. Drawing review and processing parameter setting
Before starting processing, carefully review the drawing to determine the required shape, size and accuracy requirements. According to the drawing requirements, set appropriate processing parameters, such as tool discharge gap, pulse width, pulse interval, etc. These parameters will affect the machining process and the accuracy of the final result.

3. Start electrical discharge machining
Start the Sinker EDM machine and start processing. During the machining process, high voltage pulses are applied between the tool electrode and the workpiece, resulting in spark discharge. Spark discharge converts electrical energy into thermal energy, causing local melting and vaporization of the workpiece to remove material. This process is repeated by gradually removing material to create the desired shape.

4. Monitoring and adjustment
During the entire processing process, monitor the machine’s operating status and processing results. By observing discharge phenomena, monitoring changes in processing parameters, and checking the quality and accuracy of the workpiece surface, the processing parameters are adjusted in a timely manner to ensure a stable and accurate processing process.

5. Post-processing and inspection
After completing the processing, perform necessary post-processing operations on the mold cavity or workpieces, such as cleaning and appearance inspection, dimensional inspection, etc. Use measuring tools to perform dimensional inspection and surface roughness measurement on workpieces or molds to ensure they meet drawing requirements.

How does wire EDM work?

The basic principle of wire EDM is to use a continuously moving thin metal wire (called an electrode wire) as an electrode to perform pulse spark discharge on the workpiece to erode the metal to achieve the purpose of cutting. Here’s a step-by-step explanation of how wire EDM works:
1. Wire Preparation: A thin metal wire, typically made of brass or molybdenum, is threaded through the machine’s wire guides and tensioned to ensure stability during the cutting process.
2. Workpiece Setup: The workpiece, which is the material to be cut, is securely fixed on the machine’s worktable. The workpiece and wire are positioned relative to each other based on the desired cutting path.
3. Electrical Discharge: A high-frequency pulse generator supplies a series of voltage pulses between the wire electrode and the workpiece. This creates a spark discharge, ionizing the gap between them and generating a plasma.
4. Material Removal: The intense heat generated by the plasma melts and vaporizes a small portion of the workpiece material, which is flushed away by a dielectric fluid (usually deionized water) circulating through the cutting gap.
5. Wire Advancement: As the wire electrode moves continuously in a predetermined path, it progressively cuts through the workpiece by repeatedly creating electrical discharges and removing material.
6. Control System: The WEDM machine is equipped with a control system that regulates the pulse generator, wire feed mechanism, and servo motors to maintain accurate cutting parameters such as wire tension, feed rate, and discharge energy.
7. Completion and Post-Processing: Once the desired cut is achieved, the wire electrode is stopped, and the workpiece is removed from the machine. Any necessary post-processing steps, such as cleaning, deburring, dimension inspection.
Wire EDM technology has the following characteristics:
1. The slit produced during processing is narrow and the amount of metal erosion is small, which is conducive to the reuse of materials.
2. By processing the workpiece through CNC programming technology, the processing parameters can be adjusted, making it easy to realize automatic processing.

Can you polish SPI A1 surface finish?

No problem, we have experience in polishing SPI A1, especially transparent PC, PMMA, SAN and other clear plastic materials.

What processes are involved in injection molds making?

Injection molds are generally processed through CNC milling, sinker EDM, wire EDM, polishing, etc.

What is Electrical Discharge Machining?

EDM, also known as spark machining, spark eroding, die sinking, wire burning or wire erosion. It is a process that uses the spark generated between the electrode and the part to be processed to erode the material to process the part.

Injection Mold Machining Resources
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