We receive 3D-printed prototypes and CNC-machined samples from OEM customers every week. In our factory, the transition from prototype to injection-molded production follows a documented DFM → mold design → T0 trial → T1 validation sequence. Each transition exposes design issues that worked in a print but fail in a mold — wall thickness, draft angles, undercuts. We catch these before steel is cut.
Every prototype-to-production transition in our factory follows five stages. Each stage has a go/no-go checkpoint — we do not proceed until the previous stage is confirmed.
We compare the prototype geometry (3D print or CNC sample) against injection molding requirements. Draft angles are audited — zero-draft surfaces flagged. Wall thickness mapped for sink risk. Undercuts inventoried and classified: redesign-out vs. side-action vs. lifter. Gate location trade-off evaluated against cosmetic and structural requirements.
Steel grade is selected based on production volume: aluminum for 500–2,000 shot bridge tools; P20 for 100k–300k shot production molds; H13 for 500k+ high-volume tools. We confirm steel grade, cavity count, and expected mold life before ordering material.
20 CNC machining centers machine cavities, cores, and inserts. EDM handles deep ribs and sharp corners. After fitting and assembly, the mold is mounted on one of our 45 injection machines for the T0 trial. We check fill, dimensions, surface finish, weld line placement, and ejection.
T0 adjustments are applied — process parameters tweaked or cavity geometry modified. T1 parts are measured on the CMM against every dimension on the 2D drawing. Dimensional reports and photos are shipped to the customer for approval.
Once T1 is approved, the mold enters production. Process parameters — injection speed, temperature, holding pressure, cooling time — are locked as the baseline. First-off approval at shift start, periodic sampling every 1–2 hours, and final pre-shipment inspection maintain consistency across batches.
In our factory, we routinely receive prototype designs that pass functional testing but fail moldability review. Here are the most common issues.
3D printers and CNC mills do not need draft. Injection molds do. A vertical wall that prints perfectly will drag, score, or stick during ejection from a steel mold. We flag every zero-draft surface in DFM review and recommend minimum 0.5°–1.5° draft depending on material and surface finish.
Prototypes often have thick bosses, uneven ribs, or solid sections added for printing stability. In injection molding, non-uniform walls cause differential cooling rates — producing warped parts. We recommend coring out thick sections and keeping rib thickness at 50–60% of adjacent wall thickness.
A snap-fit that works in a 3D print may require a side action, lifter, or slide in a mold — adding $1,000–$3,000 per mechanism. We evaluate every undercut: can it be redesigned out, or does it need a mechanical solution? The DFM report shows the cost impact of each choice.
| Stage | Tooling Cost | Per-Unit Cost | Typical Lead Time |
|---|---|---|---|
| 3D Printing (1–10 pcs) | $0 | $5–$80 | 1–3 days |
| CNC Machining (1–50 pcs) | $0 | $15–$200 | 3–10 days |
| Prototype Mold (Al, 500–2k shots) | $1,500–$4,000 | $1.50–$5.00 | 15–25 days |
| Production Mold (P20, 100k–300k shots) | $3,000–$15,000 | $0.25–$1.50 | 25–45 days |
| High-Volume Mold (H13, 500k–1M shots) | $8,000–$50,000+ | $0.10–$0.60 | 35–60 days |
90T–800T for prototype trials and production runs
In-house mold manufacturing without outsourcing
CMM, optical, hardness testing all in-house
No transport to external trial facility
Every prototype-to-production project lands on one of these manufacturing paths.
Real OEM projects: home appliance, medical, LED, and consumer product transitions from DFM to production.
45 machines from 90T to 800T. Mold trials, sampling, and volume production in one factory. DFM review included before every project.
In-house mold design, 20 CNC machining centers, CMM inspection. Prototype molds in aluminum, production molds in P20/718H/H13 steel.
Send your CAD file (STEP/IGES) and prototype photos. Our engineers will compare your design against mold requirements, flag every issue, and deliver a mold plus production quotation within 24 hours.