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Wire Harness Plastic Injection Mold
The wire harness plastic injection mold is engineered for producing high-precision cable management components including connector housings, junction boxes, cable clips, strain reliefs, and grommets. This tooling system supports insert molding of terminals, crimped contacts, and pre-assembled wire subassemblies. 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 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 complex geometries. Ejection strategies combine ejector pins, air poppets, and a synchronized stripper system to ensure damage-free demolding of intricate components.
Core advantages
- Insert molding capability for terminals, contacts, and wire subassemblies
- Collapsible core technology for internal locking and TPA features
- Pinpoint gate hot runner with individual nozzle temperature control
- Multi-cavity configurations (4+4, 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%
- Terminal positioning tolerance ±0.015 mm with optical verification
Product characteristics
| Mold base standard | DME / HASCO / FUTABA |
| Insert molding capability | Terminals, contacts, wire subassemblies |
| Injection materials | PA6, PA66, PBT, POM, LCP, PP |
| Clamping force range | 50 – 800 ton |
| Number of cavities | 4 – 16 (custom) |
| Surface finish | SPI A1, VDI 3400, textured |
| Terminal positioning tolerance | ±0.015 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
- Harness board mounts and tie-downs
- Splice housings and wire management systems
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 metal 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
