Multi-Cavity Plastic Injection Mold with 24/32/48 Cavities and High Efficiency Hot Runner System for 35% Cycle Time Reduction

KDET specializes in multi-cavity plastic injection mold design and manufacturing, delivering high-output tooling solutions that dramatically reduce per-part cost for high-volume production. With cavity configurations from 24 to 48 cavities and integrated hot runner systems, our multi-cavity molds achieve cycle time reductions of up to 35% compared to single-cavity or cold runner alternatives. Since our founding in 2007, we have manufactured over 2,000 multi-cavity molds for clients in automotive, packaging, medical, and consumer goods sectors worldwide.

Our multi-cavity mold solutions are engineered to maximize production efficiency while maintaining tight dimensional consistency across all cavities. Every mold undergoes rigorous mold flow analysis to ensure balanced filling, uniform cooling, and consistent part quality from every cavity in every cycle.

• Balanced Cavity Design: Every multi-cavity mold is engineered with computational flow balancing to ensure identical fill time, pressure, and temperature across all cavities, maintaining consistent part weight and dimensions within ±0.05mm.
• Integrated Hot Runner System: Valve gate or hot tip hot runner systems eliminate cold runner waste, reduce cycle time by 15%-35%, and enable automatic degating for lights-out production capability.
• Conformal Cooling Channels: Optimized cooling circuit design with baffles and bubblers reduces cooling time by 20%-30%, directly improving overall cycle efficiency and mold throughput.
• Family Mold Capability: We design family molds that produce different components of the same assembly in a single shot, reducing tooling investment and simplifying inventory management for multi-part assemblies.
• Interchangeable Insert System: For products with variants, our interchangeable cavity insert design allows quick changeover between versions without replacing the entire mold, saving retooling costs.
• Proven Mold Longevity: Manufactured from premium hardened tool steels (H13, S136, 718H) with nitriding treatment, our multi-cavity molds consistently deliver 500,000 to over 1,000,000 shots before major maintenance.

• Packaging Industry: Bottle caps, closures, thin-wall containers, and dispensing pumps requiring multi-cavity production for high-volume output with consistent seal integrity.
• Medical Consumables: Pipette tips, syringe barrels, specimen containers, and petri dishes manufactured in 32-48 cavity configurations meeting ISO 13485 cleanliness standards.
• Automotive Connectors: Wire harness connectors, sensor housings, and electrical terminals produced with 24-cavity molds to IATF 16949 specifications for automotive supply chains.
• Consumer Electronics: Earbud casings, USB connector bodies, remote control buttons, and small precision components requiring high cavitation for cost-effective mass production.
• Fasteners & Hardware: Wall anchors, cable clips, furniture connectors, and plastic rivets produced in high-cavity configurations for construction and furniture industries.

• Mold Flow Analysis: 2-3 working days — Simulation of fill, pack, cool, and warp to optimize gate location and cavity balancing
• Mold Design: 5-8 working days — Complete 3D design with cooling channel optimization and ejection system engineering
• Mold Manufacturing: 20-30 working days — Precision machining, heat treatment, EDM, wire cutting, and assembly
• Trial & Validation: 2-3 working days — T0 sample run with full cavity-to-cavity dimensional report
• Mass Production: Continuous — With proper maintenance schedule every 100,000 shots