How To Extend The Service Life of Injection Molds

1. Optimize Mold Design & Manufacturing

Material Selection

• Use high-quality mold steels (e.g., H13, S136, NAK80) based on production needs (plastic type, expected cycles).

• Apply surface treatments (chrome plating, nitriding, PVD coating) to enhance wear and corrosion resistance.

Structural Design

• Avoid sharp corners and thin walls to minimize stress concentration.

• Ensure uniform cooling channel distribution to prevent thermal deformation.

• Optimize draft angles and ejection mechanisms to reduce wear.

Precision Machining

• Use high-precision techniques (e.g., wire EDM, mirror polishing) to minimize surface defects.

• Proper heat treatment (quenching, tempering) is essential to avoid residual stress.

2. Control Injection Molding Process

Proper Machine Settings

• Avoid excessive injection pressure, speed, or temperature to reduce mechanical and thermal stress.

• Optimize cooling and holding time to prevent overheating.

Material Handling

• Use dry and clean plastic pellets to avoid abrasive contaminants.

• For corrosive plastics (e.g., PVC, flame-retardant grades), clean residues regularly.

Mold Preheating

• Preheat molds before production (especially large molds) to prevent thermal shock cracks.

3. Regular Maintenance & Care

Cleaning & Rust Prevention

• Clean mold surfaces, runners, and ejector pins after each shift.

• Apply anti-rust spray before long-term storage.

Lubrication

• Lubricate moving parts (e.g., guide pins, sliders) with high-temperature grease (e.g., molybdenum disulfide).

Inspection & Repair

• Check for scratches, rust, or cracks periodically.

• Replace worn components (e.g., ejector pins, inserts) before they cause further damage.

4. Proper Handling & Management

Operator Training

• Avoid manual hammering or forced ejection.

• Use robots for part removal to minimize human errors.

Mold Tracking

• Maintain records of mold cycles, repairs, and issues for predictive maintenance.

5. Surface Enhancement Technologies

• Coatings (TiN, DLC): Improve hardness and corrosion resistance.

• Laser Repair: Restores worn areas with precision.

6. Smart Production Planning

• Rotate multiple molds for high-volume production to avoid overuse.

• Use older molds for trial runs to preserve new ones.

Conclusion

By implementing these best practices—optimizing design, controlling process parameters, performing regular maintenance, and using advanced coatings—you can significantly extend mold life (often beyond 500,000 cycles). The key is preventive care to avoid irreversible damage and ensure long-term efficiency.