Custom Mold Design Service
Our mold design provides complete mold design solutions for processes such as injection molding and blow molding. It reduces the number of mold trials, ensuring product consistency and stability in production.
Booling's Manufacturing Solution for Vacuum Cleaner Motor Housings
Booling leverages over a decade of technical experience in precision mold manufacturing and is a supplier for BYD’s headlamp and taillamp mold development projects. This collaboration focuses on providing BYD with complex automotive lamp molds and products to meet BYD’s stringent requirements for light distribution, surface quality, and mass production efficiency.
Challenges And Difficulties
Precision Requirements
BYD’s vehicle models feature matrix LED headlamps and through-type taillamps, which include complex light guide strips. The mold surface requires ultra‑high gloss polishing (SPI A1 grade) and precise optical geometry to ensure uniform light distribution without dark spots or bright lines.
Multi-Material Molding
BYD’s lamp assemblies incorporate many materials, such as transparent PC, black housings, and chrome‑plated trims, all integrated into a single component. This requires not only advanced multi‑shot injection molds but also precise rotary or core‑back mechanisms.
High-Volume Production
BYD’s monthly vehicle production reaches tens of thousands of units or more, and dimensional accuracy must remain consistent from one production run to the next.
Short Development Cycle
Mold development, try‑out, and optimization must be completed within 45–60 days.
Solutions
Optical Simulation And Mold Design
Booling’s engineering team works together with BYD’s optical designers, conducting mold flow analysis to optimize gate locations and cooling channel layouts, minimizing warpage to ensure optical precision.
High-Precision Mold Manufacturing
Using 5‑axis CNC machining and EDM processes, Booling achieves mold cavity surface roughness below Ra 0.05μm.
Advanced Multi‑Shot Tooling
For combination lamp assemblies, Booling’s multi‑shot molds can produce 2‑color and 3‑color parts in a single cycle, increasing production efficiency by 40% compared to traditional assembly methods.
Quality Traceability
All process parameters can be recorded, enabling full traceability from raw material batch to final assembly.
Mold Design Services We Offer
Custom Injection Mold Services
We provide mold design services for injection molds, including gate design, edge gate, hot runner, and more.
Custom Stamping Die Services
We provide mold design services for stamping dies, extending die life and improving material utilization in die manufacturing.
Our Mold Design Process
Product Analysis and DFM Report
At this stage, we can provide customers with feasibility assessments including wall thickness evaluation, draft angle, and undercut analysis.
Mold Structure Concept Design
At this stage, we can determine the parting line, number of cavities, and gate type for the product.
Simulation Verification
At this stage, we can perform cooling analysis, flow analysis, and structural strength verification for the product.
Design Drawings
At this stage, we can provide 2D assembly drawings and 3D mold drawings for the product.
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