Mould Tool Manufacture
The mould tool manufacturing process is overseen by our dedicated teams to guarantee that it meets the precise requirements of each project.
From the injection moulding tool design phase through to tooling production, every step is carefully managed to ensure that the project remains on schedule and within the established budget.
We understand the importance of transparency and communication, which is why we keep our customers informed about the progress at every stage. This includes detailed updates and access to the complete schedule for the tool's build, trialling, and validation phases.
By providing this level of insight and involvement, we ensure that our customers are confident and satisfied with the injection mould tooling process, knowing that their specific needs and expectations are being met at every turn.
Technical. Competitive. Experienced
A well-engineered mould tool not only ensures precision and efficiency but also enhances its longevity, laying the foundation for consistently high-quality parts. At Amtek, many of our team members, including our managing director, started their careers as tool makers. This extensive experience in mould tooling gives us a deep understanding of tool design and manufacturing, enabling us to collaborate seamlessly with trusted tool makers to deliver high-quality injection mould tooling.
By maintaining full control over the design and specifications, we ensure that each tool meets our strict quality standards. This collaborative approach allows us to offer cost-effective, flexible solutions that don’t compromise on quality, enabling our clients to achieve the best possible outcomes for their projects. Whether it’s prototype tooling for small batches or multi-cavity tools for high-volume production, we manage every step of the mould tooling process to ensure that it meets the exact needs of each client.
Precision At Every Stage
The design of an injection mould tool is a critical and highly detailed process that demands precision at every stage. We rigorously review every element of the tool's design to ensure it meets the highest standards. We start by considering the specific requirements of each project, from material selection to part geometry, and assess all variables, such as parting lines, gate locations, cooling channels, and ejection mechanisms. Each aspect of the design undergoes thorough analysis and iterative adjustments to optimise efficiency, durability, and functionality. Throughout the design phase, we collaborate closely with our injection mould tool makers, running simulations and flow analyses to predict and correct potential issues before tool manufacturing begins.
By working with advanced CAD software and leveraging decades of design experience, we ensure that every tool is engineered for optimal performance.
UK Quality
Our dedicated team specialises in delivering high-quality injection moulding solutions, ensuring that every injection mould tool we create is meticulously designed to meet precise specifications. From initial design to final delivery, every tool is optimised for performance, longevity, and cost-effectiveness. Our approach combines decades of experience in tool design and manufacturing with advanced technology and industry-leading techniques, allowing us to provide reliable, cost-effective solutions for both prototypes and high-volume production.
We prioritise clear communication and proactive project management, ensuring on time delivery and the highest quality standards. Our hands-on approach guarantees that each mould tool is ready for reliable, repeatable production, improving the consistency and efficiency.
We pride ourselves on offering a comprehensive, end-to-end injection moulding service tailored to the unique demands of each industry we serve. We manage every aspect of the process, from initial design review, in depth DFM analysis and tooling through to production and post-moulding services. Our in-house capabilities allow us to oversee every stage with thorough quality control, ensuring each part meets our high standards for precision and consistency.
We operate advanced injection moulding technology that accommodates both low and high-volume production needs, with flexibility for complex and multi-cavity mould tools. Our expertise spans a range of industries—including automotive, medical, aerospace, and electronics—and enables us to support specialised applications with engineering-grade materials, precise moulding techniques, and detailed testing. Additionally, we offer secondary operations like assembly and packaging.
Full-Service
Mould Tooling
The manufacturing process of every injection mould tool at Amtek is meticulously scheduled and closely monitored at every stage to ensure precision and quality. Once the design is finalised, the tool moves into production, where skilled engineers and tool makers begin the fabrication process, paying attention to every minute detail. From CNC machining and EDM to polishing and texturing, each phase is carefully managed to ensure the plastic injection tool meets the stringent specifications and tolerances required. Throughout this process, our team works collaboratively, with each stage of manufacturing documented and reviewed to maintain control over quality and timelines.
To guarantee the tool’s readiness for mass production, members of our team regularly travel to our tool making facilities in the Far East. These visits allow us to oversee trials, conduct thorough evaluations, and provide real-time feedback on the tool’s performance. Before the tool is shipped back to the UK for mass production, our team ensures that it has passed all our necessary checks and that it can be approved and signed off. This direct involvement allows us to address any issues early, ensuring that the tooling will perform at the highest level once it enters full-scale production. This hands-on approach is consistent with best practices where close collaboration and rigorous monitoring at each step of the mould tooling process are key to achieving reliable, repeatable, and cost-effective production
Tailored Solutions
We work closely with our clients to carefully assess and determine the most suitable mould tooling specifications, fully customised to meet the specific requirements of each product and project. Our team takes the time to evaluate important factors, including cavitation levels, the type of steel hardness required, and whether a hot or cold runner system would be most effective for the application. Each decision is made with precision to ensure the tool performs optimally and efficiently.
To meet the diverse needs of our clients, we offer a variety of injection mould tooling options. Whether you're looking for a solution for high-volume production or a more cost-effective choice for smaller runs, we tailor our offerings to fit different production needs and budget considerations. By balancing performance and cost, we help our clients achieve the best results while staying within their desired specifications. This flexibility ensures that every project, large or small, receives the right tooling solution to meet its unique demands.
Design for Manufacture (DFM)
A key step in any new tooling project is the Design for Manufacturability (DFM) process for the component itself. This process involves a detailed evaluation of the part design to ensure it is optimised for efficient manufacturing. We collaborate closely with our clients to assess key design elements such as material selection, wall thickness, part geometry, and tolerances, all of which play a crucial role in the tool’s performance and manufacturability. We also focus on factors like ease of assembly, cost-effectiveness, and potential for high-quality production.
During this phase, we conduct a thorough review of the component's design, addressing crucial aspects like mould flow analysis, gate placement, part ejection, and other critical design features that can impact the overall functionality and manufacturability of the tool. By incorporating feedback from our clients and leveraging our extensive expertise, we ensure that the component design is not only manufacturable but also optimised for both performance and cost-efficiency in production, setting the foundation for a smooth and successful tooling process.
Tool Design
Once the part design is finalised, we move on to the Tool General Assembly (GA) review stage, where our expertise in injection mould tool design comes into full play. Our team’s deep knowledge of injection mould tooling and decades of hands-on experience ensure every aspect of the tool design to meets our exacting standards. We work closely with the toolmakers to refine and optimise the design for performance, manufacturability, and durability.
Throughout this stage, we conduct thorough reviews, examining every element of the tool design, from material selection to cooling channels, ejection methods, and gate placement. We focus on eliminating potential issues early, ensuring that the tool can be produced efficiently and reliably. Our proactive approach allows us to incorporate design improvements that directly impact the tool’s cycle time, longevity, and overall performance.
In addition to meeting the client’s specifications, we bring an extra layer of precision and expertise to the process, ensuring that the final tool design aligns perfectly with our own high standards for quality, functionality, and manufacturability. This attention to detail helps us achieve cost-effective production, consistent quality, and successful, repeatable runs.
Tailored Solutions
We work closely with our clients to carefully assess and determine the most suitable mould tooling specifications, fully customized to meet the specific requirements of each product and project. Our team takes the time to evaluate important factors, including cavitation levels, the type of steel hardness required, and whether a hot or cold runner system would be most effective for the application. Each decision is made with precision to ensure the tool performs optimally and efficiently.
To meet the diverse needs of our clients, we offer a variety of injection mould tooling options. Whether you're looking for a solution for high-volume production or a more cost-effective choice for smaller runs, we tailor our offerings to fit different production needs and budget considerations. By balancing performance and cost, we help our clients achieve the best results while staying within their desired specifications. This flexibility ensures that every project, large or small, receives the right tooling solution to meet its unique demands.
Design for Manufacture (DFM)
A key step in any new tooling project is the Design for Manufacturability (DFM) process for the component itself. This process involves a detailed evaluation of the part design to ensure it is optimized for efficient manufacturing. We collaborate closely with our clients to assess key design elements such as material selection, wall thickness, part geometry, and tolerances, all of which play a crucial role in the tool’s performance and manufacturability. We also focus on factors like ease of assembly, cost-effectiveness, and potential for high-quality production.
During this phase, we conduct a thorough review of the component's design, addressing crucial aspects like mould flow analysis, gate placement, part ejection, and other critical design features that can impact the overall functionality and manufacturability of the tool. By incorporating feedback from our clients and leveraging our extensive expertise, we ensure that the component design is not only manufacturable but also optimized for both performance and cost-efficiency in production, setting the foundation for a smooth and successful tooling process.
Tool Design
Once the part design is finalized, we move on to the Tool General Assembly (GA) review stage, where our extensive expertise in tool design comes into full play. Our team’s deep knowledge of injection mould tooling and decades of hands-on experience ensure every aspect of the tool design to meet our exacting standards. We closely collaborate with the toolmakers, using our expert insights to refine and optimize the design for performance, manufacturability, and durability.
Throughout this stage, we conduct thorough reviews, examining every element of the tool design, from material selection to cooling channels, ejection methods, and gate placement. We focus on eliminating potential issues early, ensuring that the tool can be produced efficiently and reliably. Our proactive approach allows us to incorporate design improvements that directly impact the tool’s cycle time, longevity, and overall performance.
In addition to meeting the client’s specifications, we bring an extra layer of precision and expertise to the process, ensuring that the final tool design aligns perfectly with our own high standards for quality, functionality, and manufacturability. This attention to detail helps us achieve cost-effective production, consistent quality, and successful, repeatable runs.
Optimising Production
Our expertise in injection mould tooling allows us to optimise production processes, reduce waste, and minimise costs for clients. Through efficient injection mould tool design and manufacturing, we ensure improved performance, cycle times and extended tool life, ultimately leading to cost-effective solutions. This approach enables us to offer competitive pricing while maintaining high-quality standards, helping businesses achieve faster time-to-market and higher returns on their investment.
Comprehensive Support
From the initial tool design to production and beyond, you will receive dedicated support at every stage of the tooling process. Our tailored scheduling, regular updates, and committed project team ensure that you are fully informed and supported. You can trust that at Amtek, we are dedicated to your success, with a focus on delivering high-quality, efficient solutions tailored to your specific needs.
Maximising Efficiency
While injection mould tooling can be a significant upfront investment, our expertise and efficiency in tool design and manufacturing help optimise production workflows, reduce waste, and drive overall cost savings for our clients. We ensure that each tool is designed to maximise performance and longevity, ultimately lowering operational costs. This allows us to offer highly competitive pricing and cost-effective solutions so our clients receive the best value without compromising on quality.
Always Up-To-Date
We have unique project scheduling and tracking tools that keep our customers informed at every stage of the injection mould tooling process. Our system provides real-time updates, ensuring clients have visibility into the progress of their projects from start to finish. By offering clear timelines, milestone tracking, and proactive communication, we keep manufacturing processes on track and minimise any potential delays.
"Their expertise and attention to detail have made them a key partner"
"We trust Amtek with all our mould tooling projects. Their ability to handle both simple and complex designs has improved our production efficiency and reduced costs"
"Amtek are an essential partner in our tooling projects. Their expertise in complex mould designs and efficient production has ensured we consistently meet tight deadlines while maintaining exceptional product quality"
"Amtek have helped us meet demanding production schedules with excellent quality"
Tool Trial And Validation
Mould tooling is the creation of bespoke moulds that produce the parts in plastic injection moulding. The moulds consist of both moving and fixed platens which are clamped together at the beginning of the process. Molten plastic is then fed into the clamped mould at a very high pressure. Air is then pumped into the mould to ensure the plastic is uniformly covering the entire mould cavity. The plastic is then cooled and hardened within the mould before the platens release and the mould tool opens. This is a very rapid process.
Typically, these injection moulding moulds would be constructed from hardened steel due to steel’s strength and hard-wearing properties. The choice of injection mould material depends on the mass production volume. For example, steel moulds are more expensive to construct but they have a longer lifespan which offsets the initial mould tooling costs, therefore, hardened steel moulds are suitable for higher injection moulding production volumes. At Amtek we tend to steer clear of aluminium moulds as we are set up for quality high volume manufacturing.
UK Mould Tool Trial
We will work closely with you throughout the process, from initial design consultations to final injection mould tooling production. Here at Amtek we utilize UK, European and Chinese mould tooling manufacturers, ensuring flexibility and cost-effectiveness for your project.
Initial Production
While injection mould tooling can be a significant investment for businesses, our expertise and efficiency in injection mould tool design and manufacturing can help optimize production processes and minimize waste, ultimately saving clients time and money. This allows us to continue to offer competitive pricing and cost-effective solutions.
Support & Maintenance
You will be supported throughout the tooling process from initial injection mould tool design to production and beyond with tailormade scheduling, regular updates and a dedicated project team. You can be rest assured that you are working with a business who is committed to your success.
Have Tooling Already?
We can help. We guide you through the entire process of transferring your mould tooling to us, whether within the UK or internationally. Our team ensures minimal manufacturing downtime during the transition, streamlining the process to keep your operations running smoothly. From start to finish, we provide a seamless service and aim to be more than just a supplier – we strive to become a trusted partner in your business’s success.