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Automotive Wire Harness Injection Mold
The automotive wire harness injection mold is engineered for producing precision components for cable management systems including connector housings, junction boxes, cable clips, strain reliefs, grommets, and wire routing guides. This comprehensive tooling system supports insert molding of terminals, contacts, and pre-assembled wire subassemblies, as well as overmolding processes for encapsulated cable assemblies. The mold architecture incorporates sliding cores, collapsible cores, and hot runner systems with pinpoint gating to achieve precision fill in complex geometries. 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 wire management components.
Core advantages
- Insert molding capability for terminals, contacts, and wire subassemblies
- Overmolding and encapsulation 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, contacts, wire subassemblies |
| Injection materials | PA6, PA66, PBT, LCP, PPS, POM, TPE |
| Clamping force range | 50 – 800 ton |
| Number of cavities | 4 – 16 (custom) |
| Surface finish | SPI A1, VDI 3400, textured |
| Wire encapsulation tolerance | ±0.05 mm |
| Mold life | 1M – 3M shots |
Application scenarios
- Connector housings and terminal retainers
- Junction boxes and fuse block enclosures
- Cable clips, clamps, and routing guides
- Strain reliefs and cable glands
- Grommets and sealing elements
- Encapsulated wire harness assemblies
- Harness board mounts and tie-downs
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
