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Automotive Cable Connector Mold
The automotive cable connector mold is engineered for producing high-precision connector housings, terminal position assurance (TPA) components, cable seals, and strain relief elements. This tooling system supports insert molding of stamped terminals, crimped contacts, and pre-assembled wire subassemblies. The mold architecture incorporates sliding cores, collapsible cores for internal locking features, and hot runner systems with pinpoint gating to achieve precision fill in thin-wall connector sections. Steel selection includes Stavax ESR for polished cavity surfaces and H13 with PVD coating for wear-prone insert areas. Cooling employs conformal circuits with micro-channel technology to maintain dimensional stability across complex connector geometries. Ejection strategies combine ejector pins, air poppets, and a synchronized stripper system to ensure damage-free demolding of intricate terminal housings and seal retainers.
Core advantages
- Insert molding capability for stamped terminals and crimped contacts
- Collapsible core technology for internal TPA and locking features
- Pinpoint gate hot runner for precision fill in thin-wall sections
- Multi-cavity configurations (8+8, 12+12, 16+16) available
- PVD coating (TiAlN, CrN) on slide and core surfaces
- Conformal micro-channel cooling reduces cycle time by 20–28%
- Terminal positioning tolerance ±0.015 mm with optical verification
Product characteristics
| Mold base standard | DME / HASCO / FUTABA |
| Insert molding capability | Stamped terminals, crimped contacts |
| Injection materials | PA6, PA66, PBT, POM, LCP, PC |
| Clamping force range | 60 – 600 ton |
| Number of cavities | 4 – 16 (custom) |
| Surface finish | SPI A1, VDI 3400, textured |
| Terminal positioning tolerance | ±0.015 mm |
| Mold life | 1M – 3M shots |
Application scenarios
- Sealed and unsealed connector housings
- Terminal position assurance (TPA) components
- Cable seals and wire sealing elements
- Strain relief housings and cable glands
- PCB header connectors and pin headers
- Sensor connectors and mounting flanges
- High-voltage connector systems
Processing considerations
- Mold temperature: 80–120°C for PA; 60–100°C for PBT
- Melt temperature: 260–300°C for PA; 230–260°C for PBT
- Insert preheat temperature: 120–180°C for metal terminals
- Injection profile: slow fill to prevent terminal displacement
- Pack pressure: 50–80% of injection pressure, hold time 3–8 sec
- Venting depth: 0.005–0.010 mm for precision connectors
- Shrinkage allowance: 0.5–1.2% for PA; 0.4–1.0% for PBT
