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Connector Housing Injection Mold
The connector housing injection mold is engineered for producing precision thermoplastic housings for automotive electrical connectors, including sealed and unsealed connector systems, header connectors, and wire-to-board interfaces. This tooling system supports insert molding of terminals, seals, and pre-assembled contacts. 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 housing 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. Ejection strategies combine ejector pins, air poppets, and a synchronized stripper system for damage-free demolding of intricate housing geometries.
Core advantages
- Insert molding capability for terminals and seal elements
- Collapsible core technology for internal locking and TPA features
- Pinpoint gate hot runner with individual temperature control
- Multi-cavity configurations (4+4, 8+8, 12+12, 16+16)
- PVD coating (TiAlN, CrN) on slide and core surfaces
- Conformal micro-channel cooling reduces cycle time by 20–28%
- Housing wall thickness tolerance ±0.02 mm
Product characteristics
| Mold base standard | DME / HASCO / FUTABA |
| Insert molding capability | Terminals, seals, contacts |
| Injection materials | PA6, PA66, PBT, LCP, PPS, POM |
| Clamping force range | 50 – 600 ton |
| Number of cavities | 4 – 16 (custom) |
| Surface finish | SPI A1, VDI 3400, textured |
| Wall thickness tolerance | ±0.02 mm |
| Mold life | 1M – 3M shots |
Application scenarios
- Sealed connector housings for engine compartment
- Unsealed connector housings for interior applications
- Header connectors and PCB mounting housings
- Wire-to-wire and wire-to-board connector housings
- Sensor connector housings and mounting flanges
- High-voltage interlock connector housings
- Custom connector housing solutions
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 housings
- Shrinkage allowance: 0.5–1.2% for PA; 0.3–0.8% for LCP
