Automotive Blow Molding Side Step Mold Manufacturing Service
Model: BL2505160 | Die Ref: F5120S
Booling manufactures automotive blow molding side step molds for SUV and commercial vehicle projects. Through optimized parting surface design, integrated cooling circuits and long cavity structural optimization, we effectively control surface flash, wall thickness unevenness and parting gap deviation during long-term mass production.
- ISO 9001:2015 Certified
- List ItemQuote Within 1 Working Day
- Quote Within 1 Working Day
- Full After-sales Support
- 6100 m² Workshop
- 10+ Years Manufacturing
- 12-Month Warranty
- 24h Response
Side Step Blow Molding Molds Adaptable to Different Mass Production Volumes
Forming Technology of Booling Automotive Side Step Blow Molding Molds
Parison Wall Thickness Control and Melt Flow Analysis Optimization Technology
H13 Composite Wear-Resistant Cutoff Surfacing Machining Technology
5-Axis Integrated Seamless Cavity Machining Technology
Customer Testimonial
The BL2505160 mold delivered exceptional cycle time reduction — 43 seconds vs. our previous 68-second benchmark. T1 samples passed on first try with all 12 dimensional checkpoints within tolerance.
Technical Drawings & 3D Models
UNIQUE PER CASE — Drawing package provided per project. Contact sales for your DFM & CAD package.
Steel Grade Selection for Blow Molding Side Step Molds
P20 (First Choice)
H13
S136
- Hardness Standard: HRC 34–38;
- Application: Anti-slip texture appearance surfaces of side steps, humid storage areas.
- Selection Reason: It achieves ultra-high mirror polishing performance and excellent corrosion resistance, effectively protecting mold surface textures from erosion during overseas transportation or storage in humid factory areas.
Delivery Process and Documentation Package for Automotive HVAC Duct Mold System
- Hardness Standard: HRC 28–32
- Application: Short-cycle medium and small-batch side step projects.
- Selection Reason: This steel grade requires no heat treatment, offering higher processing efficiency. Side steps formed with polished molds feature flat and bright appearance, effectively compressing processing cycles and controlling mold opening costs.
Precision Assurance for Blow Molding Side Step Mold Machining
We own a full set of mold processing and testing equipment, stabilizing dimensional tolerances at the micron level:
| Machining Process Category | Machine Axis Count | Maximum Machining Dimension Specification | Machining Precision Grade | Core Application for Blow Molding Molds |
|---|---|---|---|---|
| Double-Head High-Precision EDM | 5-axis | 3000×1500×800 mm | ±0.015 mm | Suitable for ultra-long integrated cavity side steps. Deep reinforcing ribs, sharp undercuts inaccessible to milling cutters are all formed in one EDM operation. The cavity avoids splitting into multiple assembled inserts to eliminate assembly gaps, minimizing flash on mass-produced products and lowering manual trimming costs. |
| 5-Axis CNC | 5-axis | 500×400×400 mm | ±0.005 mm | High-precision machining of cutoff thread details, mounting bosses and blow pin seats. The sealing gap is stably controlled at the micron level, resulting in slight wall thickness fluctuation for mass-produced products, eliminating assembly gaps and overflow defective parts. |
| 3-Axis CNC | 3-axis | 410×410×410 mm | ±0.003 mm | Mass unified processing of EDM copper electrodes and cooling water channel threaded joints, featuring high processing efficiency, reducing electrode manufacturing costs for customers and shortening mold delivery cycles. |
| Wire Electrical Discharge Machine | 4-axis | 400×300×300 mm | ±0.003 mm | Machining of cutoff sliding inserts and cooling water channels. Uniform and regular assembly gaps of inserts ensure no mold sticking or water channel leakage during later mass production. |
| Precision Surface Grinder | — | 600×300 mm | 0.001 mm/300 mm | Overall precision grinding of large-area parting surfaces of long side steps to achieve micron-level flatness, solving overflow and excessive mold closing gap issues in mass production. |
| Coordinate Measuring Machine (CMM) | — | — | Calibration-Grade Precision | Complete 3D full-size scanning of samples after mold trial to verify straightness and assembly tolerances, with complete dimensional inspection reports fully delivered in one batch. |
| Heavy-Duty Blow Molding Trial Machine | — | Single station | Mass Production Simulation Grade | Custom parison programs matching your production line, fully replicating operating conditions of your mass production equipment to avoid repeated mold debugging after molds arrive at your factory. |
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Delivery Process & Document List
| Phase | Cycle | Core Work | Acceptance Standard | Documents Delivered in This Phase |
|---|---|---|---|---|
| DFM Review | 3–5 Days | Receive OEM 3D models, PV test standards and annual output volume; conduct melt flow / parison sag / cooling simulation and output lightweight schemes. | Customer signs to confirm DFM report, all risk points rectified and closed. | Gantt chart of development plan, special characteristic list, melt flow simulation report. |
| Mold Design | Week 2–3 | Complete design of single or dual cavities, H13 cutoff edges, double-end blow pins and conformal cooling water channels; steel grade selection confirmed. | Complete set of 2D/3D drawings and steel scheme confirmed by customer. | Complete mold drawings, cooling simulation report, PMI inspection plan for steel materials. |
| Precision Machining & Assembly | Week 4–6 | 5-axis CNC / 5-axis EDM / Wire EDM / Surface Grinding; IQC spectral inspection of steel materials, full IPQC inspection of each process, air tightness test after assembly. | No air leakage, no mold sticking during insert assembly, all dimensional inspections passed. | Process dimensional inspection records, steel material certificate, original air tightness test data. |
| T0 Mold Trial | Early Week 7 | Replicate customer mass production equipment to debug parison programs; CMM scanning of wall thickness and straightness. | No fatal forming defects, wall thickness and impact performance qualified, all defect list items closed. | T0 mold trial rectification report, segmented parison process parameters, multi-section wall thickness comparison table. |
| T1 OTS Delivery Mold Trial | Week 7–8 | Customer witnesses on-site mold trial, OTS samples produced, low-temperature impact and load durability tests completed. | Dimensions and performance of OTS samples fully qualified, customer signs release. | FAI full-size CMM report, qualified OTS samples, third-party low-temperature impact test report. |
T1 Trial Results
UNIQUE PER CASE — Drawing package provided per project. Contact sales for your DFM & CAD package.
T1 Qualification — All Checkpoints Passed
- Dimensional: All 12 points within ±0.01 mm
- Functional: 0.8 MPa leak test — passed
- Flash trim: Clean break, no burr
- Dimensional: All 12 points within ±0.01 mm
- Functional: 0.8 MPa leak test — passed
- Flash trim: Clean break, no burr
Performance Comparison
UNIQUE PER CASE — Drawing package provided per project. Contact sales for your DFM & CAD package.
| Aspect | BL2505160-F5120S | Industry Average |
|---|---|---|
| Cycle Time | Sample #1 | 65–70 seconds |
| Dimensional Tolerance | Sample #2 | Sample #2 |
| Mold Life | Sample #2 | Sample #2 |
| Auto Demolding Rate | Sample #2 | Sample #2 |
Booling Quality Assurance System
We manufacture in strict accordance with ISO 9001:2015 standards covering the whole process from DFM review to mold shipment. Every drawing revision records complete modification date, person-in-charge and customer signature. All dimensional deviations and surface defects occurring during mold machining and trial are recorded, and our engineers conduct review and revision to avoid recurring identical faults.
Incoming Quality Control (IQC)
Provide steel material certificates and conduct on-site verification with PMI spectrometers to ensure qualified base mold materials and H13 cutoff inserts.
In-Process Quality Control (IPQC)
Dimensional inspection is carried out for each process. The flatness of parting surfaces is strictly controlled within ≤0.03 mm, and cavity assembly gaps ≤0.02 mm. Process cards are signed and circulated to eliminate flash and wall thickness defects during machining.
In-House Mold Trial
Mass production simulation is performed on trial machines, and CMM three-coordinate inspection is conducted for long cavity dimensions and straightness.
Final Quality Control (FQC) After Assembly
Strict inspection of closed height, multi-point cutoff gap and air tightness after mold closing test. We fully retain actual measured air tightness test data.
Outgoing Quality Control (OQC) Before Shipment
Final inspection of appearance and opening/closing functions before packing.
Overseas Transportation Protection Scheme for Export Molds
Booling complies strictly with automotive industry standards for logistics protection and technical service specifications:
High-Standard Sea-Grade Anti-Rust and Sealing
Custom long-acting anti-rust oil is sprayed on the cavity, parting surfaces and insert slots of ultra-long side step molds, followed by overall sealing with heavy-duty industrial vacuum bags filled with sufficient industrial desiccants. This isolates high salt spray and high humidity during ocean transportation, fundamentally preventing oxidation and rust of P20, H13 or S136 steel grades.
High-Standard Sea-Grade Anti-Rust and Sealing
Molds are packed in customized ISPM 15 compliant heat-treated or solid wooden cases lined with high-density shock-absorbing foam. TiltWatch tilt indicators and ShockWatch shock indicators are affixed outside each case to monitor loading, unloading and transportation quality throughout cross-border logistics.
Technical Drawings & 3D Models
UNIQUE PER CASE — Drawing package provided per project. Contact sales for your DFM & CAD package.
DFM report
- Wall Thickness Analysis：To check whether the wall thickness distribution of the product is uniform.
- Demolding：Whether the demolding process goes smoothly.
Material Selection: Able to select appropriate materials based on the product’s functional and appearance requirements.
Assembly: To check whether there are any assembly issues when the product is assembled with other components.
Mold flow analysis
Optimize gate location :Determines the best position for injecting plastic into the mold to ensure complete filling.
Predict filling patterns :Visualizes the advancement of the melt front, identifying potential air traps and weld lines.
Cooling behavior : Evaluates temperature distribution and cooling time to reduce warpage and shorten cycle time.
Identify shrinkage and warpage : Predicts areas prone to sink marks or deformation after cooling and solidification.
Evaluate packing pressure : Assesses the holding pressure maintained during cooling to compensate for material shrinkage, sink marks, dimensional inaccuracies, or internal voids.
Reduce mold trial iterations : Minimizes the number of physical mold trials, saving both time and cost.
Mold design
Mold trial
Defect Diagnosis and Troubleshooting: Identifying various defect issues that occur during the trial molding stage and eliminating them.
Comprehensive Inspection: Performing dimensional accuracy measurements, appearance checks, material property tests, and assembly trials on the samples.
Performance Testing: Evaluating the flow rate and pressure of the mold’s cooling system, the filling balance of the mold, and other relevant conditions.
Recording: Documenting all key molding parameters for the first batch of samples produced.
Small-batch production and sample delivery
Quality Inspection: We will randomly sample products from each batch of small-scale production to conduct comprehensive dimensional accuracy measurements, appearance inspections, and material property tests.
Defect Handling and Improvement: If any defects occur during the production process (such as bubbles, warpage, dimensional deviation, etc.), we will immediately conduct a root cause analysis for the customer and adjust the mold manufacturing process and other means until the defects are eliminated.
Sample Delivery: According to the customer’s requirements, we will clean, deburr, and apply rust-proof treatment to some samples, and use shock-proof and anti-static packaging to ensure no damage during transportation.
After-sales service
- Technical Training Services：Our technicians have professional skills and relevant knowledge to support online mold maintenance guidance, conduct rapid troubleshooting, and assist in mold processing and processing of difficult-to-process engineering plastic raw materials.
- Regularly inspect and evaluate the mold ：our after-sales personnel can understand the customer’s usage in a timely manner and make corresponding suggestions.
- Repair & Warranty：We guarantee the quality of molds and provide first-level maintenance and second-level maintenance services. If you encounter any problems within the warranty scope, we will provide accurate and correct repair services to ensure that customers have the shortest downtime and quickly re-enter the production process.
Cooperation Process for Custom Side Step Blow Molding Molds
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You only need to submit part 3D drawings, annual output volume and vehicle model requirements.
duration: 3–5 days
+
Finalize mold price, trial shot quantity, delivery cycle and spare parts list with you.
From ~60% baseline → 30% improvement
+
Steel purchasing is initiated immediately upon receipt of deposit.
From ~60% baseline → 30% improvement
+
Mass production simulation debugging on trial machines, with retained CMM scanning reports of wall thickness and straightness.
duration: 3–5 days
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You may witness on-site mold trial or receive shipped samples. Shipment of export molds is arranged after full qualification confirmation.
From ~60% baseline → 30% improvement
Custom Automotive Side Step Blow Molding Mold Customization Solutions
Share your side step product drawings or physical samples, we will deliver professional cost quotation and customized DFM optimization report within 24 hours.
Booling After-Sales Support Service
Spare Parts Package
Spare middle-section cutoff inserts, blow pins, O-rings, water pipe connectors and zoning control valves are delivered together with molds, matched for conventional maintenance within 12 months.
Remote Video Technical Support
For any sudden process abnormality on your production line, our project engineering team will conduct on-site remote troubleshooting via high-definition video calls at the earliest opportunity to assist your workshop operators in quickly resuming production.
Lifetime Cost-Price Supply of Wearing Parts
Even years after mold delivery, if you need to replace any mold components worn under normal production, Booling will supply parts at pure factory cost without profit to reduce later mold maintenance costs and production downtime frequency.
Mold Warranty
All molds are covered under a 12-month full mold warranty. Within this period, free repair or upgraded replacement services are provided for any mold failure caused by manufacturing defects.
Drawing Revision Support
When OEMs revise duct geometry (typical 2D to 3D updates or wall thickness adjustments), we quote engineering modification costs based on a fixed rate instead of rebuilding from scratch.
Production Capacity Reservation
For long-term production customers, we reserve machine time on our EBM (Extrusion Blow Molding) production lines to support urgent trials in case of unexpected mold downtime.
With years of development experience in automotive side step blow molding molds, Booling supplies automotive blow molding side step molds to top-tier OEM suppliers, satisfying mass production demands ranging from small and medium batches to large volumes. We provide full-cycle technical support covering preliminary DFM design, high-precision manufacturing, mold delivery and overseas remote debugging.
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