How We Work

Our Injection Molding & Mold Manufacturing Process

How We Proceed

At ACO Mold, we follow a structured, transparent workflow to guide your project from initial concept to final delivery. Our process ensures seamless transitions between each phase, guaranteeing predictable lead times and consistent quality for both custom injection molds​ and contract molding services.

From injection mold order confirmation to completion, we follow a standard procedure to ensure both internal teams and customers are always clear about the project status. We guarantee smooth transitions between each step. Here is how we start and complete your injection mold project:

 

Consultation and Quotation

Since our business focuses on customization to meet exact demands, understanding unique requirements is crucial. We generally cooperate in two ways: injection mold making only​ or contract molding (molds + plastic parts). Both are welcome; our sales manager will propose the better choice for your case or present both options for comparison.
To initiate a quotation, please provide the following:
Basic information

▪Material (e.g., ABS, PC, LSR)
▪Color
▪Surface Finish

Drawing

▪3D Drawing (STEP, IGS, X_T)
▪2D Drawing (PDF, DWG, DXF)
▪Physical Samples (Optional)
▪Pictures (Optional)

Demand

▪Quantity Forecast
▪Application Description


Packing requirement

▪Retail Packing
▪PE Bags + Carton Box


Mold Design and Manufacturing (Tooling)

This phase transforms your idea into a physical tool. We emphasize Design for Manufacturability (DFM)​ to prevent costly mistakes before machining begins.

Step 1: Kick-off Meeting & DFM Report

 

▪ Once the order is confirmed and final 2D/3D drawings or physical samples are received, the project manager holds a kick-off meeting with mold designers and mold makers.

▪ We issue a Design for Manufacturability (DFM)​ report includes necessary information about part optimization, such as proper draft angles, wall thickness analysis, and warpage analysis. It also determines the mold design concept and manufacturing process. Details to be discussed and decided include:

  • Injection machine tonnage
  • Gating and filling method
  • Ejection system
  • Cavity layout
  • Mold parting line
  • Cooling line design
  • Special structures (sliders, angle lifters)
  • Finish of mold core/cavity and engraving
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Step 2: Injection Mold Design

 

▪ After all details in the DFM are discussed, mold design commences. The design will be completed and provided to the customer within 2-3 days, depending on mold complexity and size. 

▪ Customer-specific mold requirements are always welcome.

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Step 3: Mold Manufacturing

 

▪ The mold design is sent to the customer for approval. It may take 1-2 rounds of discussion to finalize details. For contract molding projects, customers can leave these details to us.
▪ Upon design approval, we order mold steel, mold bases, and accessories. A process report showing manufacturing plans will be submitted. We provide weekly progress reports​ to keep you updated.

Lead Time:​ Typically 3-6 weeks, depending on mold size and complexity.

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Step 4: First Mold Trial (T1)

 

▪ The initial trial verifies if all mold mechanisms work properly and if part geometry is correct. We check the cooling system, injection system, ejection system, and filling performance.

▪ After modification, T1 molded samples​ are submitted to the customer along with a dimensional report, injection molding parameters, and a sampling report. The goal is 95%+ perfection​ at this stage.

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Step 5: Improvements and Second Trial (T2)

 

▪ We gather feedback regarding sample verification (functionality, appearance, dimensions). Mold modifications address these issues one by one. After corrections, we apply texture/polishing and re-make samples for final approval.

Goal:​ 1-2 sampling rounds before mold approval.

▪ Note: Part design adjustments from end customers may lead to mold modification.

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Step 6: Thorough Verification Prior to Shipping

 

▪ A final thorough check is performed before shipping, and records are kept. We conduct a short automatic run and CPK report study​ to ensure tooling stability and confirm no issues exist when the mold runs in your factory.

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Step 7: Packing and Preparation for Shipping

 

Molds are packed in wooden boxes. For sea shipments, we pay special attention to vacuum packing​ to prevent rust. Packages include:

  • 2D/3D mold design drawings
  • NC programming data
  • Spare parts and interchangeable inserts
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Step 8: After‑Service

 

▪ We follow up on mold performance in the customer’s factory and provide necessary services. We offer free replacements or cover extra costs for damages due to non‑operational causes for export molds. For molds stored in‑house for production, we provide a lifetime warranty.

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Molding Production

Quality Standard Established
1
Setup for Injection Molding
2
Quality Audit
3
Packing and Shipping
4
After‑Service
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Injection Molding Parts Weight Inspection
Quality Standard Established
According to the sample acceptance process, mold engineers create an acceptance standard covering:
Packing method, Material verification, Appearance and measurement, Tolerance confirmation, Assembly test and functionality test. 
This acceptance standard report is submitted to the customer for approval.
Precision Injection Molding Parameter Monitoring
Setup for Injection Molding
Preparation of plastic resin and the injection mold, along with injection machine reservation, takes place. We set up the mold and adjust injection parameters for stable production.
IPQC (In‑Process Quality Control)​ is conducted throughout production according to golden samples and the acceptance standard.
Tolerance accuracy inspection of injection molded parts
Quality Audit

A final inspection is conducted according to the established acceptance standard, and the inspection report is submitted to the customer prior to shipping.

packing
Packing and Shipping

We provide various shipping services and terms. Products are packed in carton boxes and placed on pallets to ensure safety during transit.

Good After‑Service
After‑Service

We guarantee consistent high quality. In case of any claims, we react immediately—solving the problem first and negotiating the details later.

Frequently Asked Questions (FAQ)

Please free no hesitation to ask questions.

A: “Mold Making Only” means we design and manufacture the injection mold for you, then ship the mold to your facility for production. “Contract Molding” (Turnkey) means we handle everything—from mold creation to mass production of the plastic parts—and ship the finished goods to you.

A: Please provide your 3D CAD model in STEP, IGS, or X_T format, along with a 2D drawing in PDF, DWG, or DXF format. If you don’t have digital files, physical samples are also acceptable for reverse engineering.

A: Our standard lead time for mold manufacturing is typically 3-6 weeks, depending on the mold complexity, size, and cavity number. We provide weekly progress reports to keep you updated throughout the process.

A: We follow a strict workflow including DFM analysis, T1 trial samples, and dimensional inspection reports. For mass production, we implement IPQC (In-Process Quality Control) based on “Golden Samples” to ensure consistency.

A: Yes. For molds manufactured and kept in-house, we offer lifetime warranty and maintenance. For export molds, we guarantee against non-operational damages and provide spare parts and technical support.

Send RFQ Now

Please contact us using the form below or by emailing sales@acomold.com

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