Case Study

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Large Mold Machining Case Study

Large molds are used to manufacture oversized industrial components requiring extreme structural strength and high dimensional stability.

large mold machining case studymold die cnc machiningcnc machine for mold manufacturing

Case Overview

Core project data for this machining case.

Industry Automotive / EV / Industrial Manufacturing

Product Large-Scale Mold System

Material P20 / H13 / 1.2738 / 718H / Cast Steel Blocks

Process Heavy CNC Milling + Gantry Machining + EDM + Precision Grinding

Machine Model HYR VMC1165 / Large Gantry CNC Systems

Tolerance +/-0.003-0.008 mm

Surface Finish Project based

Application Automotive Panels / EV Battery Structures / Structural Housing

Customer Background

Production context behind the case.

This project comes from a Automotive / EV / Industrial Manufacturing manufacturing requirement for Automotive Panels / EV Battery Structures / Structural Housing. The buyer needed stable machining quality, repeatable inspection results and a machine configuration suitable for real production rather than a one-time sample.

Machine Selection

Why this machine configuration was selected.

HYR-CNC selected the machine plan around part size, material, tolerance, surface finish, tool capacity and expected production volume. The recommended setup focuses on rigidity, spindle stability, fixture access, tool change efficiency and inspection control.

Problem

Machining problem to solve

Large molds combine:Heavy Structural Engineering+Ultra-Precision Machining+Thermal Deformation Control+Multi-Stage Assembly Accuracy

Solution

HYR-CNC machining plan

The customer is a global industrial manufacturing group producing:EV battery tray systemsAutomotive body panelsStructural housing componentsIndustrial machine enclosuresAnnual production:

Machine Used

Recommended machine configuration

Machine: HYR VMC or gantry CNC system selected according to mold size, steel hardness and accuracy target

Process: Rough machining, stress relief, semi-finishing, EDM support, polishing preparation and inspection

Accuracy Control: Thermal stability, fixture rigidity, finishing allowance control and CMM inspection

Cost Method: Published with existing website assets first to keep implementation cost low

Process

Timeline from raw material to inspection.

01 Material preparation

02 Rough machining

03 Stress relief

04 Finish machining

05 Inspection

Full Case Article

Machining background, difficulty and solution logic.

Quick Facts

Item

Details

Industry Automotive / EV / Industrial Manufacturing Product Large-Scale Mold System Materials P20 / H13 / 1.2738 / 718H / Cast Steel Blocks Process Heavy CNC Milling + Gantry Machining + EDM + Precision Grinding Machine HYR VMC1165 / Large Gantry CNC Systems Tolerance +/-0.003-0.008 mm Mold Weight 1T - 50T+ Application Automotive Panels / EV Battery Structures / Structural Housing

Introduction

Large molds are used to manufacture oversized industrial components requiring extreme structural strength and high dimensional stability.

Unlike standard molds: Small Mold -> Precision Micro SystemLarge Mold -> Structural Manufacturing System They directly determine: Vehicle body structure EV battery housing integrity Industrial equipment shells Aerospace structural parts

What Is A Large Mold?

A large mold is a heavy-duty mold system designed for high-tonnage injection molding or forming of large structural components.

Ultra-Large Mold BaseReinforced Core SystemHeavy Cavity BlocksMulti-Point Ejection SystemHigh-Stiffness Alignment System

High-Tonnage Injection / Forming ForceLarge Material Flow DistributionStructural Cooling & StabilizationLarge Part Formation

Basic structure: During production:

Customer Background

The customer is a global industrial manufacturing group producing: EV battery tray systems Automotive body panels Structural housing components Industrial machine enclosures Annual production: Millions of large structural parts per year Key requirements: Ultra-high rigidity Large-scale dimensional stability Thermal deformation control Long mold life (millions of cycles) High safety factor

Why Large Mold Machining Is Extremely Difficult

Heavy Structural Engineering+Ultra-Precision Machining+Thermal Deformation Control+Multi-Stage Assembly Accuracy

Large molds combine:

Challenge 1

Thermal Deformation in Large Structures Large steel blocks: Expand unevenly Cool inconsistently Warp under machining stress Result: Micron-level deviation becomes millimeter-level error

Challenge 2

High-Weight Structural Stability Mold weight: 1 ton -> 50+ tons Issues: Machine deflection Gravity distortion Fixture instability

Challenge 3

Long Machining Cycle Control Large molds require: 10-30 days continuous machining Multi-stage roughing & finishing Tool wear consistency control Any interruption causes: Re-calibration errors Alignment loss

Challenge 4

Assembly Alignment Precision Large molds require: Multi-section alignment across meter-scale structures Even small misalignment causes: Mold locking failure Injection defects Structural stress concentration

EV Battery Tray Mold

Function: Structural battery enclosure forming

Automotive Body Panel Mold

Function: Door / Hood / Roof panel forming

Industrial Housing Mold

Function: Machine enclosure manufacturing

Aerospace Structural Mold

Function: Lightweight structural component forming

P20 Steel

Advantages: Good MachinabilityCost EfficiencyStable Structure

1.2738 Steel

Advantages: High ToughnessGood Polishing Performance

718H Steel

Advantages: High Hardness Pre-TemperedLarge Mold Stability

H13 Steel

Advantages: Thermal ResistanceHigh Strength

HYR VMC1165 Heavy-Duty System

Best for: Large structural molds EV battery trays Automotive body molds Features: High rigidity bed structure Thermal compensation system Heavy-load spindle stability

Large Gantry CNC Systems

Best for: Ultra-large mold bases Multi-ton structural machining Aerospace-grade molds

Step 1

Large Block Preparation Cast steel / forged blocks Stress pre-relief

Step 2

Heavy Rough Machining Remove: 70-85% Material

Step 3

Thermal Stress Relief Cycles Repeated: Heat treatment Cooling stabilization

Step 4

Semi-Finish Machining Structural shaping Alignment preparation

Step 5

Precision CNC Finishing Requirement: +/-0.003-0.008 mm (structural scale)

Step 6

Deep Hole Drilling & Cooling Channels Used for: Cooling system design Thermal stability control

Step 7

Multi-Section Assembly Alignment Section matching Structural calibration

Step 8

Final Mold Testing High-tonnage injection test Deformation measurement Cooling uniformity validation

Large-Scale CMM Measurement

Ensures: Full structure accuracy Multi-meter alignment

Laser Scanning Inspection

Ensures: Surface deviation mapping Structural integrity

Load Simulation Test

Ensures: Injection pressure resistance Structural safety

Thermal Deformation Test

Ensures: Long-cycle stability

Results

Item

After HYR CNC optimization: Before After Structural Accuracy Medium High Deformation Control Weak Stable Mold Life Standard +40% Assembly Efficiency Low High Defect Rate 3-5% 0.5%

Industrial Impact

They are the physical backbone of modern industry.

Large molds directly support: Electric vehicle industry Aerospace structures Heavy industrial systems Global mass manufacturing

HYR VMC1165

Large EV / automotive molds

Gantry CNC Systems

Ultra-large structural molds

Result

Before and after machining improvement.

Item	Before	After
Result 1	Before optimization	After HYR CNC optimization:
Result 2	Before optimization	Structural Accuracy
Result 3	Before optimization	Medium

FAQ

Common buyer questions for this case.

What is this mold case about?

This page covers large-scale mold system requirements, machining difficulty, process planning and machine selection.

Which machines are recommended?

HYR VMC850, VMC1060, VMC1165 and gantry CNC systems are selected according to mold size and machining difficulty.

Can HYR-CNC support similar mold projects?

Yes. Send drawings, mold steel, tolerance, surface finish and mold size for a suitable machining proposal.

Download brochures and technical references.

Use the download center to review machine catalogs, brochure files and supporting documents before requesting a quotation.

Open Downloads

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Need a similar CNC machining solution?

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Start Machine Selection

Large Mold Machining Case Study

Core project data for this machining case.

Production context behind the case.

Why this machine configuration was selected.

Machining problem to solve

HYR-CNC machining plan

Recommended machine configuration

Timeline from raw material to inspection.

Machining background, difficulty and solution logic.

Quick Facts

Introduction

What Is A Large Mold?

Customer Background

Why Large Mold Machining Is Extremely Difficult

Challenge 1

Challenge 2

Challenge 3

Challenge 4

EV Battery Tray Mold

Automotive Body Panel Mold

Industrial Housing Mold

Aerospace Structural Mold

P20 Steel

1.2738 Steel

718H Steel

H13 Steel

HYR VMC1165 Heavy-Duty System

Large Gantry CNC Systems

Step 1

Step 2

Step 3

Step 4

Step 5

Step 6

Step 7

Step 8

Large-Scale CMM Measurement

Laser Scanning Inspection

Load Simulation Test

Thermal Deformation Test

Results

Industrial Impact

HYR VMC1165

Gantry CNC Systems

Before and after machining improvement.

Common buyer questions for this case.

What is this mold case about?

Which machines are recommended?

Can HYR-CNC support similar mold projects?

Download brochures and technical references.

More Mold Industry machining proof.

Injection Mold Machining Case Study

Automotive Mold Machining Case Study

Die Casting Mold Machining Case Study

Related mold manufacturing resources.

Mold Die Manufacturing

Injection Mold Machining Case Study

Automotive Mold Machining Case Study

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