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.
Spoilers Produced By Booling
Spoilers typically have complex curved surfaces, support ribs, reinforcing ribs, screw bosses and other structures. During injection molding, they are prone to appearance defects such as sink marks, gas traps, and flow lines. There are also high requirements for surface roughness and painting effect.
Challenges And Difficulties
Warpage
Most spoilers are long, thin-walled parts with many mounting points and uneven rib distribution.
High dimensional accuracy
Spoilers often need to be precisely assembled with components such as the rear windshield, high-mount stop lamp, and weather strips. The dimensional tolerance at key mounting points must be controlled within ±0.15mm.
Production consistency
To meet high-volume production requirements, we typically use two-cavity or four-cavity molds. This requires that the appearance and dimensions of the produced parts be completely consistent.
Solutions
The Booling team not only achieved high quality, but also produced parts with smooth, mark‑free surfaces, free from defects and color differences, with shortened production cycles — fully meeting the customer’s requirements for high‑volume mass production.
Breakthroughs
Elimination of appearance defects
We use high-precision CAE mold flow analysis software to iteratively optimize gate locations, runner systems, and cooling circuits. By adjusting the fillet radius at the root of reinforcing ribs, setting up local overflow grooves, and optimizing the venting system, we have successfully eliminated sink marks, gas traps, and flow lines on the appearance surface.
Resolution of warpage
We use sequential valve gate hot runners to control the filling sequence of the melt, combined with independent zone temperature control of the mold, to reduce warpage.
Full-process traceability system ensures quality consistency
After each part is ejected from the mold, we use an online vision inspection system to automatically identify defects such as flow lines and sink marks, with a detection rate of 99.8%. Because multi-cavity molds are used, the produced parts are highly consistent.
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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