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Automotive Electrical Parts Injection Mold
The automotive electrical parts injection mold is engineered for producing precision electrical components including connector housings, terminal blocks, fuse boxes, relay sockets, and sensor housings. This comprehensive tooling system supports insert molding of terminals, contacts, and bus bars, as well as multi-shot processes for complex geometries. The mold architecture incorporates sliding cores, collapsible cores, and hot runner systems with pinpoint gating to achieve precision fill in thin-wall electrical components. Steel selection includes Stavax ESR for polished cavity surfaces and H13 with PVD coating for extended tool life. Cooling employs conformal circuits with thermal monitoring to maintain dimensional stability. Ejection strategies combine ejector pins, air poppets, and stripper systems for damage-free demolding of intricate electrical parts.
Core advantages
- Insert molding capability for terminals, bus bars, and contacts
- Multi-shot and overmolding process support
- Collapsible core technology for internal locking features
- Pinpoint gate hot runner for precision fill
- Multi-cavity configurations (4+4 to 16+16)
- PVD coating (TiAlN, CrN) on wear surfaces
- Conformal cooling reduces cycle time by 20–25%
Product characteristics
| Mold base standard | DME / HASCO / FUTABA |
| Insert molding capability | Terminals, bus bars, contacts |
| Injection materials | PA6, PA66, PBT, LCP, PPS, POM |
| Clamping force range | 50 – 800 ton |
| Number of cavities | 4 – 16 (custom) |
| Surface finish | SPI A1, VDI 3400, textured |
| Terminal positioning tolerance | ±0.01 mm |
| Mold life | 1M – 3M shots |
Application scenarios
- Connector housings and terminal blocks
- Fuse boxes and relay socket assemblies
- Sensor housings and mounting brackets
- ECU housings and electronic control modules
- Bus bar insulators and power distribution components
- Lighting housings and reflector assemblies
- Switch housings and control panel components
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 terminals
- Injection profile: slow fill to prevent insert displacement
- Pack pressure: 50–80% of injection pressure, hold time 3–8 sec
- Venting depth: 0.003–0.008 mm for precision components
- Shrinkage allowance: 0.5–1.2% for PA; 0.3–0.8% for LCP
