MOLD & INJECTION MOLDING CASE STUDY
Pressure-tested insert-molded plastic cover for a demanding fluid application
This large, thick-wall cover combined injection molding, eight threaded metal inserts, hydraulic side actions, post-molding machining and pressure validation. The work was planned as one controlled delivery chain—from mold concept through molding, machining and test—not as a standalone molded part.
Production component prepared for a fluid-pressure application.
ENGINEERING CHALLENGE
What made the part demanding
- Approximately 12 mm average wall thickness and a large molded mass require disciplined control of filling and cooling.
- Eight SS316 threaded nut inserts had to be retained securely during molding.
- Two hydraulic sliders were required to form the functional geometry.
- Specified water-pressure testing made leak resistance a product-level requirement, not merely a cosmetic check.
Tooling parameters
- Mold envelope: 500 × 600 × 541 mm
- Injection press: 1,000 ton
- Production cycle: approximately 7 minutes
- Two hydraulic side actions integrated into the mold design
DELIVERY PROCESS
Integrated tooling, molding and finishing control
After molding, the component went through aging and secondary operations including CNC turning, milling, boring, tapping and drilling. This sequence ensured that the final functional interfaces and threaded locations were completed after the molding stage.
Original case process imagery: injection-molding setup and insert-molded cover.
Why it matters: for thick-wall insert-molded components, the mold, molding parameters, secondary machining and validation plan must be designed as a connected process. Separating these decisions creates avoidable fit and sealing risk later in the project.
VALIDATION
Leak test
Water-pressure test at 15 bar for 10 minutes with no leakage reported.
Destructive verification
Destructive pressure testing exceeded 25 bar, providing an additional margin check beyond the working-pressure test.
Original case validation imagery: pressure-test fixture, gauges and inspected component.
FOR YOUR PROJECT
Need a molded assembly with inserts, secondary machining or pressure validation?
Share your drawing, material requirement and functional test condition. Our engineering team can review manufacturability across tooling, molding and post-processing before quotation.
