In-House Aluminum Mold and Urethane Mold Manufacturing

Expert design, prototyping, and manufacturing—delivering high-quality, cost-effective solutions tailored to your needs.

In House Mold Development Process

STEP 1

CAD File Review

We begin by reviewing your supplied 3D CAD model or developing a new one based on your product requirements. This is a critical first step in our aluminum mold and urethane mold manufacturing process, where our design team evaluates geometry, draft angles, material selection, and forming feasibility.

Our engineers work closely with you during this review to catch potential issues before they become costly problems. Early collaboration ensures your design will form properly and meet all functional requirements.

STEP 2

Material Selection

We select the optimal mold material based on your application, using wood for quick prototypes, urethane tooling board for prototypes or low-volume runs, and aluminum for high-volume production or when enhanced durability is required.

The right material selection balances your budget with performance needs. Our team considers part volume, surface requirements, and durability to recommend the most cost-effective solution.

STEP 3

Mold Design & Engineering

Using your approved CAD, we engineer the vacuum forming mold, accounting for shrink rates, trim paths, venting, and flange design to ensure clean, repeatable forming.

Every design detail affects the quality and consistency of your final parts. Precise engineering at this stage prevents common issues like warping, incomplete forming, or difficult part removal.

STEP 4

CNC Machining

Our in-house 3-axis CNC routers precisely machine the mold from the selected material, delivering tight tolerances and a high-quality finish. This advanced equipment allows us to create complex geometries and fine details that would be impossible with traditional manufacturing methods.

Keeping machining in-house gives us complete control over quality and timing. We can make adjustments quickly and ensure every mold meets our exact standards before moving to production.

STEP 5

Surface Finishing & Inspection

We sand, seal, and finish the mold to optimize part release and surface texture, whether you need a smooth gloss, matte finish, or custom texture. Before entering production, we verify dimensional accuracy, edge quality, and fit with mating components or trim fixtures.

The mold surface quality directly transfers to your finished parts. Our detailed inspection process ensures consistent results and helps identify any needed adjustments before production begins.

STEP 6

Ready for Production

Your tooling is now complete and ready for vacuum forming production. We deliver the finished product with complete documentation and are prepared to begin work forming your parts immediately.

The transition from tooling to production is seamless with our integrated approach. Our team provides ongoing support throughout production to maintain quality and address any adjustments needed.

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Aluminum vs. Urethane Mold Comparison

Aluminum and urethane are the two main materials used in mold manufacturing. Urethane provides cost-effective solutions with faster machining times and easier modifications. Aluminum offers superior durability and heat transfer properties, making it ideal for high-volume production runs.

Both aluminum mold and urethane mold manufacturing offer distinct advantages for different production needs:

When to Choose an Aluminum Mold

Aluminum becomes essential for applications requiring tight dimensional tolerances and complex surface textures. Industries like automotive and aerospace often mandate aluminum molds to meet strict regulatory standards and quality certifications. The material's thermal stability prevents warpage under temperature cycling, ensuring consistent part geometry and surface finish quality across extended production runs.

When to Choose a Urethane Mold

Urethane excels in applications where mold weight and handling matter significantly. The material's lighter weight reduces setup time and operator fatigue during frequent mold changes. Urethane also enables rapid prototyping of complex geometries that would be expensive to machine in aluminum, making it ideal for proof-of-concept work and small-batch specialty applications

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