Case study 02 · Automotive · Multi-mold tooling program

Automotive PHEV Tooling Program: Multiple Molds with Coordinated Side Actions

A multi-tool automotive program required different cavity and core layouts for long-form and intersecting features, with accessible setup and controlled release.

Project Summary

Industry
Automotive (PHEV program)
Scope
Multiple automotive injection molds in one program
Construction
Long-form and compact cavity/core layouts
Inserts
Localized inserts for compact geometry and maintenance access
Release
Multiple coordinated side actions
Design priorities
Controlled release and accessible setup

The Engineering Problem

The program covered several automotive parts with different geometry: long-form parts with a curved molding path, and compact parts with intersecting features.

Each mold therefore needed its own cavity and core layout, while keeping release controlled and the tool accessible for setup and maintenance.

Long-Form Cavity with Side Actions

For the long parts, paired cavity and core views show the release strategy before mold assembly. The long curved molding path carries multiple side-action interfaces.

Long-form automotive cavity with multiple side-action interfaces
Long-form cavity: paired cavity and core views show a long curved molding path with multiple side-action interfaces.

Compact Cavity/Core with Localized Inserts

For the compact parts, the matching mold halves use compact cavity and core construction with localized inserts. The inserts support the compact geometry, controlled release and later maintenance access.

Compact automotive cavity and core with localized inserts
Compact construction: matching mold halves with cavity, core and localized inserts.

Multi-Core Side-Action Tooling

Where features intersect, coordinated side actions form them together, while the core system stays accessible for setup.

Automotive mold with coordinated multi-core side actions
Multi-core tooling: coordinated side actions form intersecting features.

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