Mould Design
At APJ Engineering design work, we specialize in delivering world-class mould design and engineering solutions that transform your product ideas into highly manufacturable, cost-effective reality. With decades of combined experience in injection mould tooling, our team of senior mould designers and plastic flow experts works as an extension of your engineering department — providing complete 3D mould design, DFM/DFA analysis, Moldflow simulation, conformal cooling optimization, and detailed electrode & machining drawings using the latest NX, Creo, and PowerMill platforms. Whether you need a high-cavitation precision mould for medical devices, complex multi-slide tooling for automotive parts, or rapid prototype tooling with 3D-printed inserts, we ensure first-time-right designs that minimize cycle times, eliminate warpage and sink marks, and achieve tool life well beyond industry standards. From initial concept review to final steel cutting package and T0 sampling support, we are your trusted partner for faster launches, lower part costs, and zero compromises on quality. Let’s build the perfect mould for your next success — contact us today for a confidential design review.
Core Principles of Modern Mould Design (2025)
1. Design for Manufacturability (DFM) First
Start every project with DFM analysis. Key checks:
- Uniform wall thickness (ideally 1.5–3.0 mm for most resins)
- Draft angles: 0.5–2° per side (more for textured surfaces)
- Avoid undercuts or use lifters/slides only when unavoidable
- Rib-to-wall ratio ≤ 0.6 to prevent sink marks
- Proper gate location to minimize weld lines on cosmetic surfaces
2. Gate Design & Location (Still the #1 Cause of Rejects)
Common 2025 gate types ranked by adoption:
- Valve-gated hot runners (65 % of new automotive & medical moulds)
- Submarine/tunnel gates (consumer goods)
- Edge gates (simple, low-cost)
- Cashew/banana gates (deep-draw parts)
- 3-plate pinpoint gates (cosmetic parts)
Rule of thumb: Gate thickness = 0.7–1.0 × nominal wall thickness.
3. Cooling System Design – The Biggest ROI Lever
Poor cooling = longer cycles + warpage + sink. 2025 best practices:
- Conformal cooling channels (3D-printed cores/cavities) → 20-40 % cycle time reduction
- Keep coolant turbulence > 10,000 Reynolds number
- Channel diameter 8–12 mm, 1.5–2.5 D away from cavity wall
- Baffles and bubblers for deep cores
- High-conductivity inserts (Cu-Be, AMPCO 940, Ongrokt™) in hot spots
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Contact
- Comboitor
-
94442 91203
86081 75203 -
apjengineeringdesignworks@outlook.com
apjenggdesignworks@icloud.com
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