Task
Design and manufacture an injection mould for a connector insulator for serial plastic moulding. Required service life — at least 500,000 cycles.
Case study · Radio electronics · 2025
Injection mould for an electrical connector
ToolingRadio electronics2025Series production
Injection mould for moulding the insulator of an electrical connector — cavity inserts for a serial production run.
Solution
Designed the cavity inserts accounting for material shrinkage, manufactured the mould and ran trials at our own facility. Reached stable moulding parameters.
Result
The mould was handed over to serial production. Service life — over 500,000 cycles, moulding accuracy ±0.02 mm.
Specifications
Technical parameters
- Cycles
- > 500,000
- Accuracy
- ±0.02 mm
Deliverables
Mould design documentationMoulding parameter chartMeasurement reports
Process
Project timeline
01 / 04
Specification + part docs
Received the design documentation for the insulator.
02 / 04
Mould design
Cavity inserts designed for shrinkage and service life.
03 / 04
Manufacturing
Machining, EDM and polishing of the cavity inserts.
04 / 04
Trials · handover
Ran moulding trials, handed the mould over with a process parameter chart.
Photo gallery
Process documentation
Photos and measurement reports will be added once the visual material is ready. The extended pack is available under NDA.
01
Drawing
02
Process
03
Finished part
04
CMM report
Some data is withheld under our agreement with the customer. Specific parameters, photos and measurement reports are available under NDA.
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