Our depth of technical knowledge enables us to offer the most suitable tooling configuration for your product based on the form of the part, batch quantities expected and material to be processed. The mould tool is usually a one-off start-up cost and our aim is to maximise your tooling investment by manufacturing a high-quality mould, reviewed by our moulding process Technicians, that is suitable for the life of the product.
Injection moulding tool design is a crucial element in the overall success or failure of a product and is reversed engineered from your approved cad data. We will undertake an evaluation of your product for ease of manufacture and to identify any potential complications or cost savings in the tool configuration. Once the project structure and cost are agreed with you we will produce a tool specification, that is agreed by a moulding process technician with the required information to produce the full tool design. Once the tool design stage is complete our skilled team of toolmakers will undertake your tool manufacture.
• Tooling options
• Material guidance
• Optimum configuration for production demand
• Moulding process review by skilled moulding Technician
• Hot Runner systems
• Suitable ejection systems
• Time served tooling engineers
• Tool specification
• Review with moulding process Technician
• Schematic layout
• Schematic review through to approval
• Full 3d cad design (Technical Tooling)
• Detailed 2d general assembly and detail for manufacture
Consideration is given to the type of mould tool that will provide the best return on investment whilst being fit for purpose to meet your requirements. Tools will usually be made from a P20 pre-toughened steel, stainless steel or fully hardened tool steel although soft alloys can be considered for certain applications. For low volume or development, projects part owned Modular Insert Systems to fit a Pentagon universal bolster can be considered, but often the preferred method is fully owned and dedicated mould tooling with a suitable number of impressions to meet production demand.
For effective project planning having a clear understanding of the variables associated with the design and manufacture of a mould tool is essential, helping to ensure that you stay within budget and lead time expectations.
Increased impressions will reduce the price per piece but will increase the size and complexity of the mould tool. Higher impressions also require more inserts with their complex detail, and a larger bolster to house them, which can also boost the cost.
A hot runner is often the preferred choice as it reduces price per piece by improving cycle times, reducing waste, and simplifying processing. It also offers more gating options, eliminates sprue and runner components, and makes larger multi-cavity tools easier to manage. However, hot runners tend to have a higher upfront cost. Cold runners, on the other hand, may be cheaper to produce for low-cavitation tools, but have a higher piece price.
Moulding high engineering grade thermoplastics, or polymers with abrasive fillers like glass, needs harder-wearing tool steels such as 1.2363 (A2), 1.2379 (D2), CPM 10V. To achieve high-gloss and polished finishes a tool steel like 1.2083 would be required but is a more expensive tooling material.
The complexity of the part will significantly affect the cost of a mould tool. This is due to the need for more complex component designs, a longer design process, and more features, for example:
• Multi-stage ejection
• Side actions
• Inclined ejectors
• Up and aways
• Over-moulded inserts
• Unscrewing
• Collapsing cores
• Actuated cores
• Camming cores
• In mould closing
• Interchangeable inserts
• Sacrificial inserts (in high-wear or damage-susceptible areas)
• Fixed Half Ejection
• Air blast
• Air-assisted ejection
• Cavity pressure sensors
• Valve gates
• Conformal cooling
• Hand-loaded inserts
At Pentagon Plastics, we ensure every project is managed carefully from start to finish to ensure quality, efficiency, and on-time delivery.
1. Initial design and DFM review – we receive your design and carry out a Design for Manufacture (DFM) review. At this stage, we will suggest any adjustments to simply production and improve efficiency before getting final approval.
2. Tool design and planning – once the models and drawings are approved, we start tool design, perform internal reviews, and prepare the Bill of Materials.
3. Manufacturing and assembly – the materials and parts are ordered, tool inserts and plates are machined, hardened and assembled. The sensors, hot runners, and other components are fitted and ready for manufacture.
4. Testing and trialling – tools are bench-tested and signed off before trialling on the moulding site. Here we can make any adjustments and repeat until the tool is fully approved.
• Production volume
• Wear resistance
• Thermal performance
• Expected tool life
• H13 (1.2344)
• A2 (1.2363)
• D2 (1.2379)
• 1.2083
• CPM 10V
These materials offer a range of toughness, hardness, and wear resistance levels that make them suitable for many applications.For bases, plates, and bolsters, materials are selected to provide strength, stability, and ease of machining. We commonly use plate steels such as P20 (1.2311), 1.1730, 1.2085. These are suited to supporting mould structures and maintaining dimensional accuracy. If you’d like more information on available tooling materials at Pentagon and their benefits for your application, contact us today.
At Pentagon Plastics, we combine industry-leading expertise with a customer-focused approach to deliver high-quality thermoplastic moulding solutions for your needs. We work with a wide range of sectors and understand the unique needs of each. We operate under the internationally recognised ISO 9001:2015 quality management system, ensuring consistency, quality, and transparency. We are here to support you through every stage of design and production, ensuring that you choose the right material for your bespoke tooling solution.
Will I see the tool design before it’s made?
Yes. We provide design models and a DFM report for your review and approval before any tool manufacturing begins.
Can design changes be made once work has started?
Minor tweaks are possible early in the process, but significant changes later can affect lead times and cost. We’ll always explain any impact before proceeding.
How are tooling materials chosen?
Tool steel and plate materials are selected based on factors such as expected wear, production volume, and part application. We’ll recommend options backed by industry experience that balance performance with cost.
What if there’s an issue with the tool design after trials?
If issues arise during trials, our tool designers will work with you to adjust the design or the tool itself to achieve the required performance.
Your Technical Experts for bespoke Plastic Injection Moulding services including Mould Tool Manufacture and Repeat Production.
© 2021 Pentagon Plastics Group
Unit 4,
Blatchford Road,
Horsham,
West Sussex,
RH13 5QR