Dec 09,2025
The whole process strategy of mold cost control: from design, material selection to manufacturing and operation
The whole process strategy of mold cost control: from design, material selection to manufacturing and operation
Mold cost control is not a simple“Price”, but a throughout the concept, design, manufacture, use and scrap of the whole life cycle value management project. Its core lies in: under the premise of meeting the requirements of product function and life, through systematic optimization, eliminate all unnecessary waste.
Design Stage: the source of cost control (determine 70% of the cost)
Standardization and Modular design
Implementation: the establishment of internal mold base standards, insert standards, accessories standard library.
Benefits: reduce non-standard design, improve design efficiency, reduce procurement and inventory costs, easy maintenance and replacement.
Design for manufacturing and assembly
Principle: simplify the die structure, reduce the number of sliders and lifters; optimize the splicing of inserts, avoid complex angle-clearing processing; design structures that are easy to polish and maintain.
Benefits: direct reduction in machining difficulty, assembly time and subsequent maintenance costs.
Pre-application of CAE analysis
Application: before machining, using Moldflow analysis (Moldflow) software for filling, cooling, warping, structural stress simulation.
Benefit: optimization of gating system, cooling system in advance, to avoid design defects caused by repeated repair, welding, which is one of the highest rate of return on cost control inputs.
Procurement and manufacturing phases: refinement of the execution process
Scientific selection of materials and fittings
Implement the“Insert Strategy”: Die set body using economical pre-hardened steel (such as P20/718) , only in the core, cavity and other key wear parts using high-end hardened steel or cemented carbide inserts.
Parts selection: avoid“Small horse pull cart”, according to the actual life requirements to choose the corresponding grade of spring, thimble, avoid excessive configuration or due to poor quality parts caused by early failure.
Optimization of processing technology
Programming optimization: optimize CNC tool path, reduce idle time, using high-speed cutting technology to improve efficiency.
Combined Process: reasonable use of high-speed milling, slow walking wire, discharge, grinding and other advantages of different processes to ensure accuracy and efficiency to find the best balance.
The use and maintenance phase: extending the value cycle
Establish a mold maintenance system: (as described in Article 7) regular preventive maintenance can greatly extend the life of the mold, reduce the frequency of overhaul and shutdown costs, is the lowest life cycle cost strategy.
Mold modification cost assessment: for the modification needs of customers, rapid and accurate cost assessment and quotation, cost management to extend to the after-sales link.
Fourth, the construction of mold cost accounting model
Develop a transparent costing model that breaks down costs into:
Direct material cost: steel, standard parts, accessories.
Direct labor costs: design, programming, processing, assembly man-hours
Manufacturing costs: equipment depreciation, energy consumption, tool wear.
Management and risk cost: management fee, trial fee, reserve for potential mold repair risk.
This model is helpful for accurate quotation, identification of cost overruns and continuous improvement.
Conclusion:
The real mold cost control, is a need for technology, management and business intelligence coordination campaign. It requires companies to change from passive“Price negotiators” to active“Value designers”. By locking in costs at the source of design, eliminating waste in the manufacturing process, and extending value in the operation and maintenance phase, companies can not only win price competitiveness, more able to build a high-quality, high reliability and rapid response to the core competitiveness as the symbol.
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