Skip to main content

Toolmaking

For the manufacturing and maintenance of our injection molds, we rely on our in-house toolmaking department, which works in close coordination with design and production. This expertise is complemented by a trusted network of partner companies, enabling us to flexibly and reliably realize even complex tooling projects on schedule.

High-precision tool insert with two cavities – injection mold for functional plastic components in series production

Manufacturing of modern injection molds

We manufacture precision molds for prototypes, pilot runs, and series production – tailored to geometry, material, and quantity. Complex requirements such as multi-cavity or rotary table solutions are also implemented in collaboration with experienced partners.

Erosion machine machining a metal tool core in an erosion bath – high-precision machining process in mold making at Aruso-Plast

Maintenance & Servicing

Our in-house tool shop enables fast response times for repairs, modifications, and wear-related maintenance – even for molds from partner companies or provided by customers.

3D CAD design of an injection molding tool – digital development and design of mold inserts in our in-house toolmaking department

Design Support & Consulting

In close coordination with our development team, we support your part design – with a focus on demoldability, cycle time, and cost-efficiency. This ensures an optimized tooling concept right from the start.

Our Tool Shop at a Glance

CNC milling of a metal tool part with coolant supply – machining for injection molds in our in-house tool shop

Our in-house tooling expertise is seamlessly combined with trusted external partnerships – ensuring reliable results throughout every project phase.

  • In-house Toolmaking for Manufacturing and Maintenance of Injection Molds
  • Production of prototype molds for functionally representative sample parts
  • Seamless integration with design, injection molding, and quality assurance
  • Manufacturing of single-cavity, multi-cavity, and rotary table molds
  • Processing of all common tool steels and application-specific materials
  • Fast response times for repairs, adjustments, and maintenance
  • Tool-oriented consulting starting in the development phase
  • Moldflow analyses including filling and warpage studies
  • Design and production of assembly fixtures for precise component assembly
Moldflow simulation for analyzing the mold filling of a plastic component – digital injection molding optimization in the pre-series process

Moldflow Analysis in Injection Molding: Efficient Tool Design through Simulation

At ARUSO-PLAST, Moldflow analysis is an integral part of our injection mold development. By accurately simulating the molding process, we can identify and optimize flow behavior, weld lines, air entrapments, and warpage at an early stage. This allows us to develop production-ready tool designs during the engineering phase, ensuring maximum process reliability and consistent part quality. Moldflow simulation not only saves time and costs, but is also essential for defect-free series production in injection molding.

What does the mold manufacturing process look like – and what can you expect as a customer?

The mold manufacturing process typically begins with a detailed technical consultation, where we clarify your requirements regarding geometry, material, tolerances, and quantities. Based on this, we develop a tool concept that ensures efficient and reliable series production.

1. Feasibility analysis and consultation

We assess your part design with a focus on tool suitability and economic efficiency. If desired, we conduct a Moldflow simulation to optimize filling behavior and minimize warpage.

2. Tool design

Based on 3D data and agreed specifications, we create a detailed mold design – including runner system, parting lines, ejection concept, and any required sliders or inserts.

3. Toolmaking and manufacturing

The tool is manufactured in our own tool shop or in collaboration with selected partners – always under strict quality standards and project milestones.

 

4. Initial sampling and optimization

The mold is tested under real production conditions. We evaluate part quality, cycle time, and repeatability. If necessary, we make targeted adjustments.

5. Final approval and series release

Once the sampling is successful and all quality requirements are met, the tool is released for serial production. You receive the corresponding documentation and test reports.

You have a part concept or need input on tool feasibility?

Let’s evaluate together how we can implement your requirements efficiently and with manufacturing precision.

Let’s discuss your project now.

FAQ

How long does it take to manufacture an injection mold?

The lead time depends on the part, its complexity, and the type of mold required. Typically, a production mold takes between six and twelve weeks, including design, manufacturing, and sampling.

What does an injection mold cost?

The cost of an injection mold depends on complexity, part geometry, number of cavities, and requirements for service life and cycle time. For simple tools, entry-level prices start in the low five-figure range. Complex multi-cavity molds or tools with special functions may cost significantly more.

What types of injection molds are available?

Common mold types include single-cavity molds for low-volume production, multi-cavity molds for higher output, and family molds for similar parts. Additional variants include rotary table molds for multi-component injection molding, as well as tools with integrated sliders or hot runners.

What is the difference between prototype and production molds?

Prototype molds are used for small batch production or functional prototypes and are often made from aluminum or softer steels. Production molds are made from high-grade tool steel, designed for longevity and continuous use in serial production.

Can you maintain or modify third-party molds?

Yes – our tool shop also handles maintenance, repairs, and modifications on existing or externally manufactured molds. This requires a technical review of the tool documentation and design.

What information is required for mold cost estimation?

To provide a reliable cost estimate, we need 3D part data, information on quantity, material specification, tolerance requirements, and any expectations regarding cycle time or surface finish.

What role does mold maintenance play in serial production?

Regular maintenance ensures part quality and extends the service life of the mold. Wear parts such as ejectors, guide elements, or hot runner components are inspected and replaced as needed. This ensures consistent process reliability over many production cycles.