Precision Mold Design & Tooling Solutions
Shankar Industries offers complete custom mold development services engineered to turn complex component concepts into high-performing, reliable tooling. Utilizing state-of-the-art 2D & 3D mold design software, our team analyzes metal flow, cooling dynamics, and ejection systems to achieve optimal die layout before manufacturing starts.
Through die optimization and precision engineering, we produce high-durability molds that deliver faster production cycles, reduced casting defects, and significantly extended mold life. From single-cavity prototype dies to high-volume multi-cavity production tooling, we provide end-to-end tooling solutions backed by ISO 9001:2015 and IATF 16949:2016 quality standards.
Service Features
- Custom mold development tailored for aluminum die casting
- Advanced 2D & 3D CAD/CAM parametric design and modeling
- Flow analysis and thermal simulation for die optimization
- High-precision core, cavity, and runner system engineering
- High-grade tool steel selection (H13, SKD61) for maximum longevity
Key Advantages
- Faster production cycles with optimized cooling channel design
- Significantly extended mold life exceeding 100,000+ shots
- Reduced material turbulence, porosity, and scrap rates
- High-quality tooling solutions minimizing maintenance downtime
- Seamless integration with VMC/CNC precision machining
Mold Design Applications
HPDC Casting Molds
High-pressure die casting dies engineered for complex automotive and engineering components.
Multi-Cavity Tooling
High-efficiency multi-cavity dies for mass production of small to medium-sized aluminum parts.
Trim & Secondary Dies
Precision trimming dies and fixture tools for rapid flash removal and component finishing.
Mold Design & Development Process
1. 2D & 3D Modeling
Conversion of part blueprints into full 3D CAD surface models and die layout designs.
2. Flow Simulation
Computer simulation of thermal flow, gating calculation, and die stress optimization.
3. Tool Machining
High-precision VMC milling, EDM spark erosion, and heat treatment hardening.
4. Trial & Approval
First article die trial casting, CMM dimensional verification, and final mold release.
Industries Served
Automotive OEM
Tooling for engine brackets, transmission cases, gear covers, and structural mobility parts.
Home & Electrical
Molds for motor end-shields, heat sink enclosures, fan components, and electrical housings.
General Machinery
Precision dies for hydraulic pump bodies, pneumatic valve bodies, and industrial fittings.
Mold Design Specifications
| Design Capabilities | Custom Mold Development, 2D & 3D CAD/CAM Modeling |
|---|---|
| Design Software | SolidWorks, AutoCAD, Unigraphics, MoldFlow Simulation |
| Die Materials | H13 Premium Steel, SKD61, P20, Die Steel Hardened to 48-52 HRC |
| Mold Life Expectancy | Up to 100,000+ Shots with Regular Maintenance |
| Tooling Accuracy | Sub-micron precision up to ±0.005 mm |
| Quality Standards | ISO 9001:2015 & IATF 16949:2016 Compliant Tooling |
| Special Features | Conformal Cooling Channels, Automatic Core-pulling, Hydraulic Ejection |
Require Custom Tooling & Mold Design Solutions?
Consult with our tool design team to optimize your casting production cycles.
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