Custom Packaging Tooling Solutions | High-Speed Injection Molds & Components

The Problem

A packaging customer had sealing issues in a flip-top cap project because the core pins from the previous supplier showed dimensional variation of up to ±0.03 mm. This caused unstable thread engagement, leakage in testing, and delays in product launch.

What We Did

After reviewing the issue, we found that worn grinding tools and thermal distortion were affecting part accuracy.
To solve this, we remachined the core pins using Hardinge CNC lathes, controlled the tolerance within ±0.005 mm, used Böhler steel with proper heat treatment, and checked the geometry with Zeiss CMM. We also reviewed the mold flow and thread contact area to improve cap sealing performance.

The Result

The updated core pins helped the customer reach a 99.8% sealing success rate in batch trials, cut production downtime by 40%, and support a 3-year exclusive supply agreement for their premium flip-top cap line.

The Problem

A medical device customer had dimensional instability in the cores of a 32-cavity syringe mold. The variation reached ±0.015 mm, causing flash and affecting part consistency.

After review, we found that the previous supplier’s rough machining method was not suitable for the deep rib structure. Tool deflection was the main cause of the unstable core dimensions.

What We Did

We adjusted the machining process based on the part structure.

For semi-finishing, we used a Makino F5 high-speed milling machine with a 42,000 RPM spindle and kept radial engagement below 15%. For 58 HRC hardened steel, we used Sandvik Coromant CBN tools to improve cutting stability.

For rib corners, we used Sodick AQ550L EDM with 0.02 mm copper electrodes to achieve finer detail and Ra 0.1 μm surface finish in critical areas.

The Result

• Core-to-cavity matching improved to ±0.005 mm
• Flash-related rejects were eliminated
• Electrode consumption was reduced by 40%
• The customer adopted our process as their new standard