Process Technology
Injection molds are core equipment for mass production of plastic products. Zorapid focuses on the R&D and manufacturing of precision injection molds and spare parts. Equipped with high-end facilities including five-axis linkage machining centers, high-speed CNC machines, EDM and wire EDM equipment, we have built a full-chain precision process system covering design, material preparation, rough machining, finish machining, heat treatment, assembly, mold trial and acceptance, catering to diverse demands from automotive, home appliance, electronics, medical and other industries.
Five-axis Linkage Machining
Complete machining of complex curved surfaces, deep cavities and thin-wall structures in one clamping setup. It reduces clamping errors, boosts efficiency by 40% and achieves precision up to ±0.005mm.
High Speed Milling (HSM)
Spindle speed over 30000rpm. Direct finish machining for high-hardness steel (HRC50-55) with surface roughness Ra≤0.2μm, replacing traditional EDM processes.
Precision Electrical Discharge Machining (EDM)
Accurate processing for complex cavities, narrow grooves and micro features up to φ0.3mm. Adopts current 5-20A and pulse width 30-200μs, reaching mirror finish Ra≤0.02μm after polishing.
Intelligent Temperature Control Molding
Rapid Heating Cycle Molding (RHCM) technology. Heat the mold to 120-180℃ before injection and cool down swiftly after filling. It eliminates sink marks and weld lines with product yield above 99.5%.
Technical Analysis
Mold Design: Precise Modeling & Simulation
Adopt integrated CAD/CAM/CAE design system. Tolerances marked down to ±0.01mm on 2D engineering drawings. 3D assembly drawings simulate mold opening and closing movements to avoid interference risks. Mold flow analysis optimizes gates and cooling channels (8-12mm diameter, 20-30mm spacing), balances cavity pressure and shortens molding cycle by 20%-30%.
Machining Procedures: Precise Operation & Strict Layer-by-Layer Control
Rough Machining: 3-axis CNC roughing with 0.2-0.3mm machining allowance reserved to remove excess material and improve efficiency.
Heat Treatment: Vacuum quenching plus low-temperature tempering. Core mold hardness reaches HRC48-52 with deformation below 0.02mm, ensuring excellent wear resistance and dimensional stability.
Finish Machining: Five-axis high-speed CNC milling for key surfaces, flatness and roundness error ≤0.01mm. EDM for tiny features and wire cut EDM for complex mold inserts.
Polishing: Combined manual and mechanical polishing. Surface roughness Ra≤0.8μm for standard surfaces; Ra≤0.02μm mirror finish for transparent and high-gloss parts.
Core Difficulties Solved: Thin Wall, Deep Cavity & Micro Features
Ultra-thin Wall Machining
Minimum wall thickness up to 0.8mm. Adopt low-cutting-force cutters and high-speed low-feed strategy to control deformation, with pass rate over 99%.
Ultra-deep Cavity Machining
Depth-to-width ratio reaches 10:1. Multi-angle five-axis linkage cutting combined with high-pressure chip removal prevents tool breakage and surface scratching.
Micro Feature Machining
Precision EDM processing for φ0.3mm tiny holes and 0.5mm narrow grooves. Electrode wear ≤5% to ensure superior dimensional consistency.
We can handle what others cannot.
While most manufacturers are restricted by tough-to-machine high-hardness materials, easy deformation of complex structures, poor precision of micro features and technical barriers in rapid heating & cooling technology, Zorapid breaks through these four major industry bottlenecks relying on core technologies and advanced equipment.
Direct finish machining of high-hardness steel (HRC50-55)
Industry Pain Point:
Traditional procedures require roughing, heat treatment then finishing, leading to long lead time and severe deformation. Conventional equipment is incapable of processing high-hardness steel.
Zorapid Solution:
Equipped with five-axis high-speed CNC machines and imported carbide cutters, we complete finish machining on HRC50-55 steel in one single clamping without secondary heat treatment. It cuts production cycle by 30% and controls deformation within 0.02mm.
Complex Deep-Cavity Thin-Wall Molds (Depth-to-Width Ratio 10:1, Wall Thickness 0.8mm)
Industry Pain Points:
Difficult chip removal in deep cavities and easy deformation of thin walls. Traditional 3-axis machining requires multiple clampings, causing accumulated errors over 0.1mm and low qualification rate.
Zorapid Solution:
Adopt five-axis linkage combined with high-pressure cooling system. Multi-angle cutting and real-time chip removal enable one-clamping completion of deep cavity and thin-wall machining. Dimensional accuracy reaches ±0.005mm with deformation controlled within 0.01mm.
Micro Precision Components (φ0.3mm holes, 0.5mm grooves, tolerance ±0.005mm)
Industry Pain Points:
Tool breakage easily occurs during micro feature machining with hard-to-control precision. Ordinary EDM electrodes suffer heavy wear, resulting in poor dimensional consistency.
Zorapid Solution:
Adopt precision EDM, ultra-fine electrodes and intelligent wear compensation. Roundness of φ0.3mm holes ≤0.003mm, straightness of 0.5mm grooves ≤0.002mm. Dimensional consistency fully meets standards in mass production.
Rapid Heat Cycle Molding (RHCM) High-Gloss Weld-Line-Free Mold
Industry Pain Points:
Uneven cooling of conventional molds easily causes sink marks and weld lines on finished products, with surface roughness Ra≥1.6μm, failing to meet requirements of high-end decorative parts.
Zorapid Solution:
Built-in heating rods plus precision cooling channels. Heat the mold up to 150℃ before injection molding, then cool it down to 60℃ within 3 seconds after filling. Finished products achieve mirror surface finish Ra≤0.02μm with no weld lines or sink marks, and the yield rate exceeds 99.5%.
Applicable Materials (Mold Steel & Injection Plastics)
Mold Steels (Precisely selected as required)
| Steel Grade | Hardness (HRC) | Key Characteristics | Typical Applications |
|---|---|---|---|
| P20 | 28-36 | Pre-hardened, good machinability, medium polishability | Consumer goods & home appliance parts (ABS/PP/PE), Lifespan: 100,000 – 300,000 shots |
| 718H | 35-40 | Pre-hardened, polishability 6000-8000 grit, high wear resistance | Precision electronics & automotive functional parts (PA+GF / PC/ABS), Lifespan: 300,000 – 500,000 shots |
| S136 | 48-52 (quenched) | Corrosion-resistant, mirror polishability 8000-12000 grit | Transparent parts, food/medical components (PVC/PC/PMMA), Lifespan: 500,000 – 1,000,000 shots |
| H13 / SKD61 | 50-54 (quenched) | High-temperature resistant, thermal fatigue resistant, high wear resistance | High-temperature injection molding, large molds (PPS/PEEK), Lifespan: 500,000+ shots |
| NAK80 | 40-42 | Mirror polishability 10000-15000 grit, high hardness | Optical lenses, high-end cosmetic parts, Lifespan: 500,000+ shots |
Injection Molding Plastics (Suitable for Multi-material Molding)
General Plastics: ABS, PP, PE, PS — Used for home appliance housings, daily necessities and packaging containers.
Engineering Plastics: PA66, PC, POM, PC/ABS — Applied in auto parts, gears and electronic structural components.
High-performance Plastics: PPS, PEEK, PMMA — Ideal for medical, optical and high-temperature working scenarios.
Special Plastics: Flame-retardant PVC, elastic TPU — Suitable for pipes, seals and flexible parts.
Case Analysis
Case 1: New Energy Vehicle Battery Tray Mold
Material: 6061-T6 Aluminum Alloy, Size: 1200×800×50mm
Client Pain Points: Oversized dimension, 1.2mm thin wall, multi-cavity structure, flatness requirement ≤0.03mm. Traditional machining easily causes deformation and involves long production cycles.
Zorapid Solution: Adopt five-axis gantry machining center, vacuum chuck clamping and stress relief process. Perform aging treatment after roughing, and finish all finish machining in one clamping. Achieved flatness of 0.02mm and dimensional accuracy of ±0.005mm.
Achievements: Completed within 25 days, shorter than the industry average of 35 days. No deformation occurred after mass production of 100,000 pieces with a yield rate of 99.8%. Won long-term stable orders from the client.
Case 2: Medical Interbody Fusion Cage Mold
Material: S136 Steel, Size: φ20×30mm, Micro tooth groove tolerance: ±0.005mm
Client Pain Points: Strict medical-grade sterile standards, excellent corrosion resistance, high precision for micro tooth grooves and mirror surface finish required. Ordinary molds are prone to rust and fail to meet precision standards.
Zorapid Solution: Adopt quenched S136 steel, precision EDM machining for tooth grooves and mirror polishing with Ra≤0.02μm. The finished mold features great corrosion resistance and easy cleaning, with 100% qualified dimensional consistency of tooth grooves.
Achievements: Compliant with ISO 13485 certification. Zero quality defects in mass production of 500,000 pieces, winning recognition from leading clients in the medical industry.
Case 3: 5G Base Station Cavity Mold
Material: H13 Steel, cavity depth 150mm, depth-to-width ratio 10:1, wall thickness 1mm
Client Pain Points: Deep cavity & thin wall structure, high-temperature PPS injection molding, prone to deformation caused by uneven cooling. Few manufacturers in the industry are capable of this project.
Zorapid Solution: Apply five-axis linkage machining, high-pressure cooling and RHCM rapid heating & cooling technology. It ensures smooth chip removal inside deep cavities, controls thin-wall deformation within 0.01mm, and produces warp-free and sink-mark-free finished parts.
Achievements: Finished in 30 days with a yield rate of 99.6%, helping clients seize market opportunities in the 5G base station industry.
Quality Assurance
Zorapid strictly complies with international certification systems including ISO 9001, IATF 16949, AS9100D and ISO 13485, and establishes a full-chain quality assurance system covering raw material control, in-process inspection, finished product acceptance and after-sales traceability.
1.Strict Raw Material Control
We only adopt first-tier brand mold steels. All incoming materials undergo spectral composition analysis and hardness testing before being put into use.
Injection molding plastics are strictly screened with moisture content controlled between 0.02% and 0.05% to avoid impurities affecting product quality.
2. Precise In-process Inspection
We implement first article inspection, random in-process sampling and full dimensional inspection for key procedures. Equipped with CMM coordinate measuring machines with accuracy up to ±0.002mm to test dimensions and geometric tolerances.
Rockwell hardness test is conducted after heat treatment, and surface roughness inspection is carried out after polishing to ensure Ra≤0.02μm.
Full inspection on molded products is mandatory. Mass production only starts after all items including dimension, appearance and strength meet standards.
3. Finished Product Acceptance Standards
Mold dimensional tolerance: ±0.005mm, geometric tolerance ≤0.01mm.
Surface roughness: Ra≤0.2μm for regular surfaces, Ra≤0.02μm for mirror finish.
Qualified molded products are free of sink marks, weld lines and warpage with 100% dimensional consistency.
We provide full dimensional inspection reports, material certificates, heat treatment records and mold trial reports for full traceability.
4.After-sales Quality Commitment
An RFID quality traceability system is established to record every working procedure and component, enabling rapid fault location.
Delivery Speed
Supported by efficient production workflows, high-end equipment clusters and lean management, Zorapid breaks industry lead time limits to achieve ultra-fast delivery:
- Sampling & Small Batch: 1-5 pieces, delivered in 3-5 days (industry average: 7-10 days)
- Medium & Small Batch Molds: Single/multi-cavity molds, delivered in 15-25 days (industry average: 25-35 days)
- Large & Complex Molds: Deep-cavity, thin-wall and multi-cavity molds, delivered in 25-35 days (industry average: 35-45 days)
Core Guarantees for Fast Delivery
Complete Equipment Cluster
Equipped with over 10 sets of five-axis & high-speed CNC machines, 5+ sets of EDM & wire cut machines and 3 CMM devices. Round-the-clock shift operation ensures sufficient production capacity.
Optimized Workflow
Parallel operation of design, machining, assembly and mold trial cuts idle time. Standardized process templates eliminate repeated parameter adjustment.
Lean Management
Dedicated project teams track orders in full progress, update schedules daily and resolve issues promptly to avoid delivery delays.
Local Supply Chain
Raw materials and spare parts are sourced locally for stable supply with zero material shortage risks.
Advantages of Choosing Zorapid
Exclusive Core Technology
We excel at projects others cannot accomplish.Equipped with five-axis high-speed machining and RHCM technology, we solve four major industry difficulties: high-hardness steel processing, deep-cavity thin-wall structure, micro features and high-gloss weld-line-free molding.Our core technical team owns over 20 years of precision mold experience, fully familiar with high-end demands in automotive, medical, 5G and other industries.
Micron-level Precision Assurance
Machining accuracy reaches ±0.005mm, surface roughness up to Ra≤0.02μm, fully meeting strict requirements of high-end precision products.Full-process quality inspection supported by international authoritative certifications ensures stable and reliable quality.
Diversified Material Compatibility
Available mold steels: P20, 718H, S136, H13, NAK80.Compatible with general, engineering, high-performance and special injection plastics.Professional material selection guidance balances performance, service life and cost to maximize cost-effectiveness.
Ultra-fast Delivery to Seize Market Opportunities
Sampling within 3-5 days, mold delivery in 15-35 days, cutting lead time by 30%.24-hour production plus dedicated project management achieves 100% on-time delivery rate.
One-stop Full-service Solution
Integrated services covering design, manufacturing, mold trial, mass production and after-sales maintenance.Free DFM analysis, mold trial service and lifelong maintenance help clients cut costs and lower risks.
Cost-effective Direct Factory Supply
Direct manufacturer supply without middlemen, prices 10%-20% lower than market average.Long mold service life of 300,000 to 1,000,000 shots with low maintenance cost, bringing better long-term economic benefits.
Summary
As a professional manufacturer specializing in R&D and production of precision injection molds and components, Zorapid takes five-axis linkage technology as the core, precision manufacturing as the foundation, strict quality and timely delivery as the guarantee, and customer demands as the orientation.
With years of in-depth industry experience, we have overcome numerous technical challenges, delivering one-stop solutions featuring high precision, superior quality, cost efficiency and fast lead time for clients across automotive, medical, 5G, home appliance and other industries.
We adhere to the philosophy: We undertake projects others cannot handle, and excel better at what others do well. By continuous technological innovation and service optimization, we help clients strengthen product competitiveness and capture market advantages.
Going forward, Zorapid will keep focusing on precision manufacturing, break technical limits steadily, and supply higher-quality, more efficient and more reliable mold products and services to global customers.
FAQ
What is the maximum size of injection molds you can make? What is your machining precision?
We can process large molds up to 2000×1500×800mm. The machining precision reaches ±0.005mm, geometric tolerance ≤0.01mm, and mirror surface roughness Ra≤0.02μm.
What is the guaranteed mold service life?
It ranges from 100,000 to 1,000,000 shots based on different materials.
P20: 100,000-300,000 shots; S136: 500,000-1,000,000 shots.
Do you support small-batch customization? What is the MOQ?
Yes, we do. No MOQ required, orders start from 1 piece. It fully meets demands for R&D sampling, trial production and mass production.
How do you handle after-sales quality issues?
We provide 1-year warranty and lifelong maintenance service. We offer free rework and refund for qualified quality problems. Equipped with RFID traceability system for quick problem positioning. 24-hour customer response and solution provision within 48 hours.
