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Automotive Wiring Harness Mold
The automotive wiring harness mold is engineered for producing precision connector housings, terminal retainers, fuse box enclosures, and cable management components. This tooling system supports complex multi-cavity configurations with insert molding capabilities for metal terminals and seals. The mold architecture incorporates sliding cores, collapsible cores for internal geometries, 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 delicate connector geometries. Ejection strategies combine ejector pins, air poppets, and a synchronized stripper system to ensure damage-free demolding of intricate terminal housings.
Core advantages
- Insert molding capability for metal terminals and seals
- Collapsible core technology for internal snap-fit 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%
- Servo-driven core pulling with position feedback
Product characteristics
| Mold base standard | DME / HASCO / FUTABA |
| Insert molding capability | Metal terminals, seals, bushings |
| Injection materials | PA6, PA66, PBT, POM, PC, ABS |
| Clamping force range | 80 – 800 ton |
| Number of cavities | 4 – 16 (custom) |
| Surface finish | SPI A1, VDI 3400, textured |
| Terminal positioning tolerance | ±0.02 mm |
| Mold life | 1M – 3M shots |
Application scenarios
- Connector housings and terminal retainers
- Fuse box enclosures and relay sockets
- Sensor connectors and mounting brackets
- ECU housing connectors and pin headers
- Cable management clips and guides
- Harness junction boxes and splices
- Sealed connector systems with integrated seals
Processing considerations
- Mold temperature: 80–120°C for PA; 40–70°C for POM
- Melt temperature: 260–300°C for PA; 190–220°C for POM
- Insert preheat temperature: 120–180°C for metal terminals
- Injection profile: slow fill to prevent terminal displacement
- Pack pressure: 50–80% of injection pressure
- Venting depth: 0.005–0.010 mm for precision connectors
- Shrinkage allowance: 0.5–1.2% for PA; 0.8–2.0% for POM
