Top Performance - Custom Office Furniture And School Furniture Manufacturer With OEM &OEM Service.
Mold design and manufacturing
Mold Development Process
Top Performance leverages its robust R&D and manufacturing team to provide clients with high-quality mold development services. Our team members have clear divisions of labor and collaborate closely to ensure efficient operations at every stage from design to production.
Preliminary Analysis and Design
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DFM Analysis
At the outset of mold development, our professional team conducts a detailed Design for Manufacturability (DFM) analysis. This process identifies potential design issues in advance, optimizes product structures, and ensures feasibility and cost-effectiveness in mold manufacturing and subsequent production. DFM analysis encompasses comprehensive considerations from material selection to product functionality, laying a solid foundation for subsequent mold design.
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Mold Flow Analysis
Using advanced mold flow simulation software, we simulate the flow of plastic within the mold to predict potential issues such as short shots, air traps, and shrinkage. Through precise mold flow analysis, we optimize key components of the mold, including the gating system and cooling system, ensuring uniform and rapid filling of the mold cavity. This enhances product quality and production efficiency.
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Mold Design
Based on DFM and mold flow analysis, our mold design team employs professional CAD/CAM software for mold design. We focus on details to ensure each component meets high-precision requirements while balancing durability and maintainability. From cavities and cores to sliders and ejector pins, every design element is meticulously considered to achieve efficient mold operation and flawless product forming.
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Mold Manufacturing
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CNC Machining
We utilize advanced CNC machining centers, including gantry CNC and high-speed CNC machining centers, to achieve micrometer-level precision. These machines handle complex-shaped mold components, covering processes from rough machining to finish machining. By optimizing machining parameters and tool selection, we enhance efficiency and surface quality.
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CNC EDM (Electrical Discharge Machining)
For complex geometries or high-precision components, we employ CNC EDM technology. Our CNC EDM machines feature high precision and efficiency, enabling the fabrication of intricate shapes and micro-scale dimensions that are challenging for traditional machining. Through precise electrode design and control, we ensure smooth surfaces and accurate dimensions, meeting stringent mold manufacturing requirements.
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Medium Wire Cutting
Medium wire cutting is indispensable in our mold manufacturing. It achieves high-precision cutting, particularly for cavities and cores with complex geometries. Our medium wire cutting equipment ensures micrometer-level accuracy and high cutting speeds, significantly shortening mold manufacturing cycles.
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Precision Grinding
Precision grinding is critical for improving surface accuracy and finish. Equipped with multiple precision grinders, we perform high-precision grinding on mold components. By optimizing grinding parameters and wheel selection, we achieve mirror-like surface finishes, extending mold lifespan and enhancing product aesthetics.
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Bench Assembly
Bench assembly is the final stage of mold manufacturing and a key step to ensure performance. Our assembly team, with extensive experience and expertise, precisely assembles and debugs mold components. Strict control over assembly accuracy ensures seamless integration of all parts, enabling efficient production.
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Equipment Maintenance and Upkeep
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Regular Maintenance
Huang Haiping, our mold development supervisor with 20 years of industry experience, has established a scientific maintenance plan. Our technical team conducts monthly comprehensive maintenance, including cleaning, lubrication, and inspection of critical components. Regular maintenance identifies and resolves potential issues, prolonging equipment lifespan and improving operational efficiency.
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Preventive Maintenance
Beyond scheduled maintenance, we implement preventive measures. By monitoring equipment performance data, we predict potential failures and take preemptive actions. This approach minimizes downtime, reduces repair costs, and ensures production continuity.
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Mold Repair Support at Vietnam Factory
Top Performance operates a factory in Vietnam, staffed with a professional mold repair team. These technicians possess practical expertise to swiftly address mold issues during production. Whether for routine maintenance or emergency repairs, the Vietnam team provides timely support to ensure uninterrupted mold operation and client satisfaction.
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Inspection and Quality Control
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Precision Measurement
We utilize advanced 2.5D and 3D coordinate measuring machines (CMMs) to perform high-precision measurements of mold dimensions, geometry, and positioning. Accurate data identifies deviations during manufacturing, allowing adjustments to ensure compliance with design specifications.
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Quality Inspection
Strict quality inspections are conducted at every stage of mold development. From raw material checks to in-process inspections and final product verification, we maintain a robust quality control system. This ensures every mold meets client standards and delivers high-quality production.
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Team Structure
We have a professional team to provide customers with innovative solutions to meet their production needs.
R&D Team
Our R&D team comprises eight experienced engineers specializing in mold design, mold flow analysis, materials science, and manufacturing processes. With clear roles covering concept design to mold development, the team collaborates closely to rapidly respond to client needs and deliver innovative solutions.
Manufacturing Team
The manufacturing team consists of 22 skilled technicians proficient in CNC machining, EDM, wire cutting, precision grinding, and bench assembly. Strict quality control and efficient workflows ensure high-quality, high-precision molds tailored to client requirements.
Mold Development Cycle
At Top Performance, we commit to efficient and high-quality mold development. Depending on project complexity, the cycle typically ranges from 30–60 days, covering all stages from design to final quality control. By optimizing processes, enhancing equipment efficiency, and enforcing rigorous inspections, we ensure timely project completion to meet client production timelines.
Top Performance combines a strong R&D and manufacturing team, advanced technology, and extensive industry expertise to deliver high-quality molds for automotive, furniture, home appliance, and tool industries. We prioritize client-centric innovation, continuously refining our processes to ensure efficient, high-precision mold development. Our technical excellence and craftsmanship empower clients to excel in competitive markets.
Get in touch with us
Just leave your email or phone number in the contact form so we can send you a free quote for our wide range of designs!
Quality Without Compromise. Innovation Without Limits.
Contact Us
Tel: +84 0273912912
Cellphone: +84 0399873522 / +86 13631130272
Whatsapp: +84 0399873522
Website: www.topperform.com
Email: sales@topperform.com
Address: Part of land plot CN-2, area A, Quynh Giao Industrial cluster, Quynh Giao commune, Quynh Phu district, Thai Binh province, Vietnam.