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Focus on quality and deeply cultivate innovation

• 2025-07-05

Focus on quality and deeply cultivate innovation

    In daily life, from the mobile phone casings in our hands, plastic water cups at home, to various plastic parts in cars and precision plastic components in medical equipment, the birth of these plastic products almost all rely on a key link - injection molds. As the "unsung heroes" in the plastic processing industry, the quality of injection molds directly determines the precision, performance and production efficiency of plastic products. Today, let's take a look at a company dedicated to the research and development, production and service of injection molds - XX Injection Mold Company. Let's see how they have steadily advanced in this industry and won market recognition with professionalism and innovation.

Project Case_Taizhou Jiefeng Mould Co.,Ltd. (jfmoulds.com)

1、From a "small workshop" to a "professional manufacturer", twenty years of honing one's skills

    At first, the company mainly took orders for some simple plastic parts molds, such as toy wheel molds and ordinary bottle cap molds. These molds have a simple structure, low technical threshold, fierce competition and very small profit margin. Even so, the team has always adhered to one principle: "Even the simplest mold must be accurate in size and have a long service life." To ensure quality, they would rather spend more time polishing the details than deliver the goods easily. Once, a batch of toy molds had a 0.1-millimeter difference in the size of one of the cavities. Although it did not affect the use, Mr. Li still asked the team to rework all of them until they fully met the standards. It is precisely this dedication to quality that has gradually built up their reputation, and some customers have begun to come to them on their own initiative.

    With the increase in order volume, the company gradually expanded its scale. They moved into a new factory and introduced the first batch of CNC processing equipment, bidding farewell to the era of pure manual operation. In the past, relying on the master's manual grinding, at most one or two sets of simple molds could be processed in a day. With the advent of CNC machine tools, the precision can be controlled within 0.01 millimeters, and the efficiency has also increased several times. The technical department said. It was also from this time that the company was no longer content with making simple molds but turned its attention to more technologically advanced fields, such as molds for home appliances and auto parts.

    From then on, the company was officially renamed "Taizhou Jiefeng Mould Co., LTD." and established the development concept of "taking technology as the core and service as the guarantee". Since then, they have allocated 10% of their annual sales revenue to technological research and development and equipment updates. They have successively introduced advanced equipment such as 3D printers and precision testing instruments, and also established their own design team.

2、 strictly control the "three checkpoints" to ensure that every set of molds can stand the test

    In the injection mold industry, there is a saying: "Molds are the mother of industry, and quality is the life of molds." We have been able to stand firm in the fierce market competition precisely because of our excellent quality. So, how do they ensure the quality of the molds? In the boss's words, it's about "controlling three key points: design, materials, and processing."

Design Stage: Make the Mold "inherently user-friendly"

    Whether a set of molds is easy to use or not, design is the foundation. Many people think that a mold is just about pouring plastic into a cavity to form a shape, but in fact, it's not that simple. When designing, one should take into account the flow rate of the plastic, the cooling time, how to remove the parts, and even whether the mold will deform after long-term use.

    To ensure a good design, the company's design team will have detailed communication with the client to understand their needs, such as where the product is to be used? How much pressure does one need to bear? Does the surface need to be smooth? What is the production batch size? Based on this information, they will first use computer software to conduct 3D modeling, simulating the flow process of plastic in the mold to see if there are any possible problems such as incomplete filling, bubbling, or deformation. If any problems are found, make timely adjustments during the design stage.

    For instance, once a customer needed a set of molds for car instrument panels. The dashboard has a complex shape, with many tiny buttons and holes on it, and has very high requirements for precision. The design team first simulated the flow of plastic with software and found that there were several corners that were prone to incomplete filling. They adjusted the position of the feed inlet, added several auxiliary flow channels, and optimized the layout of the cooling water channels to ensure that the plastic could be evenly filled and the cooling speed was consistent. After the mold was made, the trial mold was successful at the first attempt, and the customer was very satisfied.

    Good design can make molds "inherently user-friendly", not only ensuring product quality but also enhancing production efficiency and reducing customers' production costs. Engineer Zhang said.

Material aspect: Choosing the right "skeleton" makes the mold more durable

    If design is the "soul" of a mold, then materials are its "skeleton". A set of molds can be used for several years or even over a decade. The quality of the materials directly affects its lifespan and stability.

    The company has strict standards for material selection. Commonly used mold materials include steel, aluminum alloy, etc. Steel has high hardness and good wear resistance, making it suitable for manufacturing molds with large batch production and high precision requirements, such as molds for automotive parts and medical equipment. Aluminum alloy is light in weight and dissipates heat quickly, making it suitable for manufacturing some large molds with not very high precision requirements, such as molds for household appliance shells.

    "We never look for cheap materials. We all purchase from regular manufacturers. Every batch of materials is tested to see if the hardness is sufficient and if there are any impurities." " Manager Liu from the Purchasing Department said. Once, they purchased a batch of steel. During the inspection, it was found that the hardness was slightly lower than the standard. Although the price was much cheaper, the company still decided to return it and purchase new qualified materials. Although a little cost was lost, the quality of the mold was guaranteed, and it was worthwhile in the long run. Manager Liu added.

    Apart from steel, some small parts on the mold are also crucial, such as ejector pins, guide pins, hot runner systems, etc. Although these parts are small, if their quality is not up to standard, they can easily affect the normal operation of the mold. The company will choose accessories from well-known brands to ensure that every detail of the mold is reliable.

Processing checkpoint: The truth is revealed within a millimeter

    With good design and materials in place, the next step is processing. The processing accuracy requirements for injection molds are extremely high, sometimes even down to 0.001 millimeters, which is equivalent to a few tens of a human hair's diameter. To achieve such precision, the company has introduced a series of advanced processing equipment.

    For instance, a CNC milling machine can automatically process the mold cavity according to the pattern designed by the computer, and the error can be controlled within 0.01 millimeters. Electrical discharge machine tools can process complex shapes on hard steel, such as tiny holes and curved flow channels. There are also 3D printers that can quickly produce samples of molds or complex inserts, significantly shortening the R&D cycle.

    But no matter how good the equipment is, it cannot do without human operation. All the technical workers in the company are experienced masters with many years of experience. Many of them have been working here for over a decade. They are not only familiar with the operation of various devices, but also can discover some subtle problems with their experience. For instance, when polishing the cavity of a mold, experienced masters can judge by touch whether the surface is smooth and free of scratches. This is something that machine inspection sometimes cannot replace.

    During processing, we will conduct constant inspections. We measure the dimensions once after each procedure is completed to ensure there are no errors. Finally, an overall assembly and debugging should be carried out to see if the mold can be opened and closed smoothly, if the parts can be ejected smoothly, and if the cooling system can work normally. Supervisor Chen from the Production Department said. Only when all the indicators are qualified can the mold be released from the factory.

Processing equipment_Taizhou Jiefeng Mould Co.,Ltd. (jfmoulds.com)

3、Closely Follow market demands and unlock "New Skills" for Molds

    As the requirements for plastic products in all walks of life are getting higher and higher, injection molds are also constantly upgrading. We did not stop at the production of traditional molds. Instead, in response to market demands, we continuously developed new technologies and unlocked many "new skills" in molds.

Two-color mold: Making plastic parts "Two colors in one"

    Have you ever seen such plastic parts: like mobile phone cases, which are black on the outside and red on the inside; Or children's water cups, with a blue body and a white lid. Many of these "two-color" parts are produced using two-color molds.

    The special feature of the two-color mold lies in that it has two cavities, allowing two different colors or materials of plastic to be injected successively, enabling the production of two-color parts in one molding process. Compared with the traditional method of "making one part first and then gluing another", using two-color molds for production is more efficient, the parts are more stable and the appearance is more beautiful.

    Since the company began to develop two-color molds, it initially encountered many difficulties. For instance, the fusion points of two types of plastics are prone to burrs or the colors may mix together. The technical team conducted repeated experiments, adjusted the injection time and temperature of the two types of plastics, and optimized the cavity structure of the mold. Finally, they overcame these difficulties. Nowadays, the two-color molds they produce have been widely applied in fields such as electronics, automobiles, and daily necessities, and are highly favored by customers.

Multi-chamber mold: It can produce multiple parts at one time

    For some small parts, such as bottle caps, buttons, and the shells of electronic components, the demand is large and the production batch is high. If a single-cavity mold is used, only one part can be made at a time, which is too inefficient. At this point, multi-cavity molds come in handy.

    A multi-cavity mold is like a "multiple birth" mold, with multiple identical cavities, allowing for the production of multiple parts with a single injection. For instance, the molds for manufacturing bottle caps can have 32 or even 64 cavities, enabling the production of dozens or even hundreds of bottle caps in just one minute, which significantly enhances production efficiency.

    However, the design and processing of multi-cavity molds are not simple. Because it is necessary to ensure that the dimensions of each cavity are exactly the same; otherwise, the produced parts will have differences. When designing multi-cavity molds, the company's technical team pays special attention to the distribution of the feed ports to ensure that the plastic can flow evenly into each cavity. During processing, each cavity will also be inspected separately to ensure consistent accuracy. Nowadays, the multi-cavity molds they produce have been widely applied in packaging, daily necessities and other industries, helping customers significantly reduce production costs.

4、 not only "making molds", but also "providing services"

    What they sell is not just a set of molds, but a complete solution. From the moment the customer puts forward their requirements, to the delivery and use of the mold, and then to the subsequent maintenance and upkeep, they will be fully involved throughout the process, providing considerate services.

Preliminary communication: Thoroughly understand the requirements

    Many customers, although they know what kind of products they need, are not clear about the specific requirements for molds. At this point, the company's business personnel and technical staff will communicate with the clients together and help them sort out their demands. For instance, when a customer says, "I want a plastic box," they will further ask: How big is the box? What to put in? Does it need to be heat-resistant? What kind of plastic are you going to use for it? What is the production batch size? Based on this information, they will offer suggestions to customers, such as what material of mold is more suitable and what structure is designed to be more convenient for production.

    Sometimes the customers' ideas do not quite align with the actual production situation. We will promptly point them out and help them optimize. For instance, if a customer wants to make a part with a very complex shape and it is difficult to produce it with traditional molds, we suggest that he make a slight modification to the structure. This way, it won't affect the usage and can also reduce the mold cost and production difficulty. Manager Wang from the Business Department said.

Mold trial service: Ensuring "one-time success"

    After the mold is completed, the company will conduct a trial mold first. Mold testing involves installing a mold onto an injection molding machine, injecting plastic, and checking whether the produced parts meet the requirements. If problems are found, such as incorrect dimensions or surface defects, the mold will be adjusted in a timely manner until the trial mold is qualified.

    When conducting mold trials, they will invite customers to be present to observe the mold trial process together and record the data. If the customer is not available in person, they will send the video of the mold trial and samples to the customer for confirmation. Only when the customer is satisfied will the mold be finally delivered.

After-sales maintenance: Extending the lifespan of molds

    During the use of molds, it is inevitable that some minor problems will occur, such as wear of parts and scratches on the cavity. To ensure the long-term stable operation of the molds, the company offers after-sales maintenance services. Customers can contact them at any time to explain the problems with the molds, and technicians will provide solutions based on the situation.

    In addition, the company will also visit customers regularly to understand the usage of the molds and remind them to pay attention to maintenance, such as cleaning the molds regularly, applying lubricating oil, and inspecting vulnerable parts, etc. Many customers have said that buying our molds is worry-free because there is a guarantee in the future.

5、 Looking to the future, seek development through innovation

    Nowadays, the injection mold industry is developing towards high precision, high efficiency and intelligence. We are also actively planning for the future and constantly exploring new technologies and models.

    They are researching 3D printing mold technology. The processing cycle of traditional molds is long. It may take several months to complete a complex mold. However, 3D printing can quickly produce the cavity and inserts of molds, significantly shortening the research and development cycle. At present, they have produced some simple mold samples using 3D printing technology, and the results are quite good.

    Meanwhile, the company is also promoting intelligent production. They plan to introduce Internet of Things (iot) technology, install sensors on the molds, and monitor data such as the temperature, pressure, and opening and closing times of the molds in real time. By analyzing these data through computers, they can predict possible problems with the molds in advance, carry out timely maintenance, and reduce downtime.

    Although the injection mold industry is a traditional one, it also needs continuous innovation. Only by keeping up with The Times can one avoid being eliminated by the market. Mr. Li said. In the future, they hope to achieve greater breakthroughs in fields such as precision molds and environmentally friendly material molds, provide customers with higher-quality products and services, and become a benchmark enterprise in the industry.

Conclusion

    From a small workshop to a professional injection mold manufacturer, the company's development path is a microcosm of the numerous small and medium-sized manufacturing enterprises in China. They have no earth-shattering feats, but they have always adhered to the concept of "quality first, service supreme", polishing precision in the millimeter and pursuing perfection in the details. It is precisely this dedication and perseverance that have enabled them to move forward steadily in the fierce market competition, and have also allowed us to witness the resilience and vitality of China's manufacturing industry.

    In the days to come, with the continuous advancement of technology and the constant upgrading of market demands, we believe that we will continue to focus on innovation, provide high-quality injection mold solutions for more industries, and write a new chapter for them.