Tooling and Mold Design Manufacturing Case Study

This case study outlines a manufacturing project undertaken by V Solutions Global for a U.S. client requiring a complex injection mold for a door trim panel. The project faced challenges due to a compressed launch timeline and the need to meet stringent automotive standards. The document details the end-to-end tooling process, from the request for quotation (RFQ) to the final CNC programs, which resulted in a significant reduction in lead time by nearly 29% and a 75% decrease in scrap rate. The Technical Design team developed a 3D CAD mold featuring optimized cooling channels and runner systems, validated through Moldflow analysis to minimize warpage. Additionally, the Programming team created CNC machining programs that included complete toolpath documentation and operator guidelines, easing the client's setup process. The manufacturing team's steel selection was also optimized to enhance tool life by 50% and reduce maintenance intervals, ensuring robust production capabilities.