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TIER 1 / OEM PROGRAM
Automotive Dashboard Injection Mold
2500 max ton
2M shots life
Program Overview
Dashboard injection molds are large-format production tools built for manufacturing instrument panel substrates, cross-car beam covers, defroster grilles, cluster bezels, and airbag chute panels. Tools are engineered from customer CAD data with full mold flow simulation, warpage prediction, and cooling circuit optimization before steel procurement. Deliverables include DFM analysis reports, mold design drawings, steel certificates, T1 sampling, dimensional inspection reports, and PPAP documentation packages suitable for Tier 1 and OEM submission. Production support covers cycle time tuning, dimensional capability studies, and surface finish verification against customer master samples.
Tooling Scope
Large single-cavity Family tooling Gas-assist capable Sequential valve gate
Materials
PP, PP+T20, PP+GF PC/ABS, ABS ASA, PMMA TPO, TPE
Tool Steel
P20 / 1.2311 H13 / 1.2344 1.2738 mod Nitriding / PVD
Deliverables
DFM report Mold flow analysis FAI / CMM report PPAP package
Technical Parameters
| Mold base standard | DME / HASCO / FUTABA / LKM |
| Clamping force range | 650 – 2500 ton |
| Cavity quantity | 1 – 4 (dashboard dependent) |
| Surface finish | VDI 3400, grain texture, SPI A1 |
| Hot runner | Sequential valve gate / open gate |
| Cooling | Conformal circuits / spiral baffles / bubbler |
| Ejection | Pins + air poppets + stripper plate |
| Dimensional tolerance | ±0.05 – ±0.15 mm (part dependent) |
| Design software | UG / CATIA / Moldflow / AutoCAD |
| Tool life | 800k – 2M shots |
Program Workflow
01
DFM & Quotation
Part review, draft analysis, gate location proposal, tonnage estimation
02
Mold Design
3D design, mold flow simulation, warpage prediction, cooling layout
03
Steel & Machining
CNC roughing, EDM, wire cut, grinding, polishing, texture etching
04
Trial & Validation
T1 sampling, dimensional report, warpage measurement, process tuning
05
Delivery & Support
PPAP package, spare parts, hot runner service, production ramp-up support
Quality Control Points
Steel certificate and hardness verification
CMM dimensional inspection on cavity blocks
Mold flow simulation report before steel cutting
First article inspection with full dimension report
Water circuit pressure and flow testing
Hot runner temperature uniformity validation
Warpage measurement against design target
Final sample inspection against customer master
Procurement FAQ
Q What data is required to quote a dashboard mold?
3D part data (STEP / IGES / native CAD), 2D drawing with tolerance and datum scheme, annual volume forecast, material specification, grain or texture requirement, machine tonnage available, and target cycle time if defined.
Q What is the typical lead time for dashboard tooling?
Standard lead time is 45–60 days for single-cavity dashboard substrates and 60–80 days for tools with gas assist, sequential valve gate, or complex slide systems. Lead time begins after design freeze and includes T1 sampling.
Q Which documentation is delivered with the tool?
Mold design drawings, steel certificates, hot runner manual, water circuit diagram, process parameter sheet, first article inspection report, warpage report, spare parts list, and PPAP documentation upon request.
Q How is warpage controlled on large dashboard panels?
Warpage is controlled through balanced conformal cooling design, spiral baffle and bubbler layouts, sequential valve gating, rib and boss structure optimization, and validated packing pressure profiles established during mold flow simulation.
Q What after-sales support is provided?
Support includes remote process troubleshooting, spare parts supply, wear insert replacement, hot runner service, texture restoration, and on-site technical assistance for production ramp-up when required.
Request a dashboard tooling quotation
Send part data and volume forecast to receive DFM feedback and pricing within 48 hours.
