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Casting moulds
For plastics and non-ferrous alloy casting.
Production tooling
Casting moulds, stamping dies and injection moulds from a drawing or a reference sample. A turnkey cycle — from design to commissioning at the customer's site.
Send a drawingAnatomy
What an injection mould is made of
The standard set of plates, cavity and core inserts, cooling and ejection systems. Steel grade and tool life are specified at the design stage.
MOLD · CROSS-SECTIONTOOLING / 01
01 / Scope
What the service includes
02 / 04
Stamping dies
Die sets for serial production.
03 / 04
Injection moulds
For injection moulding machines.
04 / 04
Process routing
With gauges and process parameters for the customer's line.
02 / Accuracy and Ra
Tolerances and surface finish by tooling operation
Tolerances of forming surfaces and mirror finishing. By default — general mould tolerances per GOST 22085-76.
Operation
IT grade
Ra · precision
- Finish HSC millingForming surfaces on the 5-axisIT8–IT70.8Forming surfaces on the 5-axis
- Wire EDMPunches, contour operationsIT71.6Punches, contour operations
- Sinker EDM (rough)Deep cavities, ribsIT93.2Deep cavities, ribs
- Sinker EDM (finish)Finish EDM of cavitiesIT7–IT60.8Finish EDM of cavities
- Surface grindingPlates, basesIT60.4Plates, bases
- Profile grindingGuides, mating surfacesIT6–IT50.2Guides, mating surfaces
- Diamond paste polishingFor transparent plastics, optics—0.1–0.02For transparent plastics, optics
- HoningCylindrical cooling channelsIT60.1Cylindrical cooling channels
- EDM finish (electrolytic)After the main EDMIT60.4After the main EDM
NB
Mirror polishing (Ra ≤ 0.05 µm) is a separate manual operation and requires S136 or 2316 steels.
03 / Materials
Materials and tolerance by size
Steel
HRC
Application
Life
P20 (1.2311)
30–34
Basic plastic moulds
≥ 500,000 cycles
718H (1.2738)
32–38
Heavy-duty moulds
≥ 1,000,000 cycles
H13 (1.2344)
44–52
Al / Zn die casting
≥ 250,000 cycles
S136 (1.2083)
50–54
Transparent plastics, medical
≥ 1,000,000 cycles
Cr12MoV / D2
58–62
Blanking and forming dies
Serial-grade life
XW-42 (Uddeholm)
58–62
Progressive dies
High life
04 / Tooling machinery
What we make tooling on
Machinery for forming inserts, plates, guides and finish work.
5-axis machining centre01 / 05
5-axis machining centre
Mazak VARIAXIS i-700
Complex forming surfaces in a single setup — no refixturing.
- Work envelope
- 700 × 700 × 500 mm
- Spindle
- up to 12,000 rpm
- Repeatability
- ±0.003 mm
- Tool magazine
- 30 tools
Wire EDM02 / 05
Wire EDM
Sodick AQ535L
Contour cutting of die punches and cavities with IT7 tolerance.
- Work envelope
- 500 × 350 × 250 mm
- Thickness
- up to 250 mm
- Wire
- ⌀ 0.1–0.3 mm
- Accuracy
- ±0.003 mm
Swiss-type lathe03 / 05
Swiss-type lathe
Tsugami B0206-V
Serial turning of small precision parts from bar stock — the full cycle in one setup.
- Bar ⌀
- up to 20 mm
- Spindles
- 10,000 / 12,000 rpm
- Tools
- 27 stations
- Control
- FANUC 0i-TF Plus
Surface grinder04 / 05
Surface grinder
Okamoto ACC-1224ST
Plates, bases and guides — after heat treatment.
- Work table
- 600 × 300 mm
- Accuracy
- ±0.002 mm
- Surface finish
- Ra 0.2 µm
- Magnetic table
- —
Polishing station05 / 05
Polishing station
Manual + diamond paste
Finish work on forming surfaces to a mirror finish and sealing joints.
- Surface finish
- Ra down to 0.02 µm
- Inspection
- SJ-410 profilometer
- For steels
- S136, 2316, 718H
- Application
- Optical, medical plastics
NB
Equipment class; the exact lineup and serial numbers — on request under NDA.
05 / Forming surface metrology
How we measure tooling
CMM — overall dimensions. Optical 3D scanner — forming surfaces and complex cavities referenced to the CAD model.
Primary instrument
Coordinate measuring machine
Mitutoyo Crysta-Apex S 776
- Volume
- 700 × 700 × 600 mm
- MPE-E
- (1.5 + L/333) µm
- Probe
- Renishaw scanning
- Software
- MCOSMOS / GeoMeasure
Optical 3D scanner
Hexagon AICON SmartScan
- Accuracy
- down to 5 µm
- Scanning field
- 500 × 500 mm
- CAD comparison
- ColorMap deviation map
- For moulds and cavities
- —
Surface roughness tester
Mitutoyo SJ-410
- Rz range
- 350 µm
- Resolution
- 0.01 µm
- Parameters
- Ra, Rz, Rt, Rq
- Application
- Polished surfaces
Hardness tester
Mitutoyo HR-320MS
- Scales
- HRC, HV, HB
- Inspection
- HRC verification after heat treatment
06 / DFM for tooling
8 product design rules for tooling
A checklist before sending the product drawing. These points have the biggest impact on lead time, mould life and moulding / stamping quality.
Rule 01 / 08
Draft angles
1° for plastics · 0.5° for metals · from 3° for textured surfaces
Without draft — sticking on ejection, cavity wear and marks on the product.
Rule 02 / 08
Uniform wall thickness
Thickness variation ≤ 50% · optimum 2–4 mm for plastic
Abrupt transitions → warping, sink marks, hidden stresses.
Rule 03 / 08
Fillet radii
Internal R ≥ 0.3 mm at wall joints · external R ≥ ⅓ of wall thickness
Sharp corners concentrate stress; the mould fails sooner.
Rule 04 / 08
Runner system
Hot runner — for series >50k · cold runner — for short runs
Runner balancing is critical for multi-cavity moulds.
Rule 05 / 08
Ejection system
Min. 3 ejection points, symmetrical · ejector ⌀ 3–8 mm
Asymmetry → skewing; on large areas — blade ejectors.
Rule 06 / 08
Cooling channels
⌀ 8–12 mm · distance to cavity ≥ 1.5× channel ⌀ · pitch 3× ⌀
Unbalanced cooling → warping and longer cycles.
Rule 07 / 08
Parting line
In the part plane where possible · draft away from the parting line
A complex parting line makes the mould more expensive to make and tune.
Rule 08 / 08
Material shrinkage
ABS 0.5% · POM 1.8% · PA6 1.2% · PC 0.7%
Shrinkage is built in at the mould CAD modelling stage.
07 / Drawings and formats
What to send for tooling
We accept product CAD formats and mould requirements. Shrinkage calculation and mould CAD refinement are done on our side.
Minimum drawing content
DRAWING / EXAMPLE- 01Plastic / metal grade of the product with shrinkage stated
- 02Volume and production run (for tooling steel selection)
- 03Product surface finish (Ra by zone)
- 04Tolerances of key product dimensions
- 05Surface texture (Mold-Tech / VDI 3400)
- 06Marking / branding zones on the product
- 07Ejection points (if there are requirements)
- 08Parting line (if there are requirements)
3D formats
06- ·STEP / STP (the product, preferred)
- ·IGES / IGS
- ·X_T (Parasolid)
- ·SLDPRT (SolidWorks)
- ·PRT (NX / Creo)
- ·Mould flow analysis data — if available
2D drawings
03- ·DWG / DXF
- ·PDF of the product drawing with the current revision
- ·Sketch + 3D model — DFM to be agreed
08 / Heat treatment and finishing
Heat treatment, coatings and finish
Hardening and nitriding — via partners with years of experience in tool steels. Polishing and mirror finishing — in-house.
Through trusted partners
Electroplating, heat treatment and complex coatings go to specialised shops under a defined procedure.
06
- Hardening + temperingGOST 4543 / DIN EN 10052HRC 30–62 depending on the steel
- NitridingGOST 24622 / DIN 17211Depth 0.2–0.5 mm, HV 800–1000
- TiN / CrN coating (PVD)DIN 50320Thickness 2–4 µm, +50% life
- Chrome platingGOST 9.301-86Anti-corrosion, up to 25 µm
- Chemical oxidising of steelGOST 9.305-84Protective black
- Bluing—For non-working surfaces
09 / Case studies
From real work in this area
A few case studies that show what we actually do. An extended pack with reports and process video is available under NDA.
All case studies
Tooling01 / 03
2025
Radio electronics · 2025
Mould for a CPU socket
Plastic injection moulding. Commissioning at the customer's site.
- Cycles
- > 200,000
- Accuracy
- ±0.02 mm
Open case study
Tooling02 / 03
2023
Instrumentation · 2023
Brackets, busbars, electrical contacts
Set of stamping dies with process routing and gauges for the line launch.
- Dies
- 6
- Lead time
- 3 months
Open case study
Tooling03 / 03
2025
Radio electronics · 2025
Injection mould for an electrical connector
Plastic injection moulding: connector insulator. Mould trials at our own facility.
- Cycles
- > 500,000
- Accuracy
- ±0.02 mm
Open case study
10 / Documentation
What we deliver
We hand over the full package with the tooling: documentation, process parameters, maintenance schedule and a set of spare consumables.
Tooling design documentation3D mould model (STEP)Moulding / stamping process cardTrial acceptance reportSteel and heat treatment certificatesMaintenance card
11 / FAQ
Frequently asked questions
01What tooling materials do you use?
P20, 1.2738 (718H), H13 (1.2344), S136 (1.2083) for moulds; Cr12MoV, XW-42 — for stamping dies. Selected by required life and product material.
02What is the maximum mould size?
Mould envelope — up to 600 × 600 × 500 mm. For larger moulds we involve partners with heat-treatment furnaces and heavy-duty overhead cranes.
03Do you guarantee tooling life?
The guarantee is stated in the contract, typically 100,000 cycles for P20 moulds and 250,000+ for heavy-duty ones. We support it with a maintenance schedule.
04Support after tooling handover?
Scheduled maintenance, fine-tuning after the first batches, repair on wear. Warranty period — from 12 months.
05Do you take moulds for modernisation?
Yes, we rework existing moulds: cavity/punch replacement, re-etching, runner system changes, cooling improvements.
Inquiry
Send a drawing —
we'll quote within 24 hours
Fill in the form or contact us directly — any channel works.
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