Mold Processing Center
Innovation through R&D
KST’s mold processing center is equipped with a comprehensive range of high-quality CNC machines, including CNC wire cutters, CNC internal grinding machines, as well as 2D and 3D coordinate measuring machines. These state-of-the-art CNC machines are imported from renowned manufacturers in Germany, Switzerland, Japan, and the United States, known for their exceptional dependability, stability, precision, and performance.
Moreover, our mold processing center is staffed by approximately 50 skilled technicians and engineers. To enhance the efficiency of our operations, we have implemented 12 fully integrated automatic storage and retrieval systems (AS/RS), which enables us to effectively manage a vast inventory of over 4,000 molds and more than 30,000 inventory items and finished products.
At KST, we employ a diverse range of industry-accepted software, including AUTOCAD, Pro-Engineer, Uni-Graphic, and ABAQUS. These CAD/CAM engineering and product lifecycle management software play a pivotal role in enhancing our design capabilities, strengthening our manufacturing processes, and supporting product development and lifecycle management.
With nearly 50 years of experience in mold design, KST has accumulated extensive expertise in developing products. We take pride in our impressive portfolio, consisting of approximately 30,000 products and over 4,000 sets of molds. Whether you require assistance with your existing designs or wish to collaborate on the development of new ones, KST is your ideal engineering and manufacturing partner.
We offer comprehensive technical and engineering services tailored to meet the manufacturing needs of various industries, specializing in plastic, silicone rubber, and liquid silicone rubber injection molds. Our expertise enables us to deliver high-quality products for clients across a wide range of sectors, including but not limited to automobile, lighting, medical, agriculture, and avionics.
Mold Processing Center Features & Benefits
We have experienced engineers, processes, and state of the art equipment waiting to work with you to develop your designs.
Stamping Die & Injection Mold Processing Center
Step 1
Mold Design
TWNCCAD, Alphacam
- After the Customer provides 3D Data of the product, KST designs the mold according to required material characteristics and production requirements.
- A injection mold is usually composed of two halves, the fixed cavity side, and the moving core side. The core side slides open and close.
- While designing the mold, we will use Alphacam CAD/CAM software to simulate the process and validate mold design.
Step 2
Mold Scheduling & Dispatch
ERP / Automated Storage Retrieval System (ASRS)
- Production Management receives and registers the design drawing.
- ERP system provides estimate, projects delivery schedule and assigns barcode identification
- Provides Input-output processing operation control
Step 3
CNC Machine Center (MC)
Kafo VMC-850
Injection Mold
- Order 3rd Party Steel Blocks for cavity and core main inserts
- Use a milling machine to mark the position of screw holes and cooling lines
Drill through holes for cooling lines - Block the end of through-holes with aluminum plugs to form cooling loops
- Cut off residual aluminum
Stamping Mold
Step 4
CNC In-hole Grinding
GE Fanuc Series 16i-M, Hauser S45 Jig Grinder
CNC machining of the core and cavity insert can take several hours each.
Step 5
CNC Wire Cutting EDM
TWNCAD, Agie Cut200, Seibu M500S
We use wire EDM machines to cut through holes for ejectors. The precise ejector can go through holes to ensure accurate sizing thus avoiding flash issues during the injection molding process.
Step 6
CNC Optical Grinding & Forming
Waida PGX-2500SP
This SPG-X standard profile optical grinder offers improved ease of operation and visibility. The projector is manufactured under rigorous quality control to deliver visibility and reassuring support. The new standard-equipped LED transmitted illumination provides clear projections. Meets various grinding needs due to a wide range of optional equipment available
Step 7
CNC 3D forming – Electrode Making
Vertical Milling & Boring Machining Center AV-70S
- Complex shapes in steel can not be achieved by CNC milling. Instead, this can be achieved using Electrical Discharge Machine (EDM). The electrodes are important to the EDM process.
- We use CNC machines to cut the copper blocks which can take several hours to achieve the specified shape.
- The quantity of electrodes required is determined by the complexity of the mold. For instance, hundreds of electrodes are required for some molds.
- Each piece is individually CNC machined, and subsequently deburred
Step 8
CNC Die-sinking EDM
Mitsibushi EA8PV Die-sinking EDM
Material is eroded from the material workpiece by means of a pulse discharge between electrodes and steel insert submerged in water. The electrode and steel insert are close to each other but never touch.
Step 9
Plane Grinding
Emery paper, wet stone, and ultrasound are used to polish and remove EDM and CNC process imperfections and provide a uniform finish of the cavity and core/die form.
Step 10
Precision Coordinate Measuring Machine (CMM)
Zeiss Prismo
Our accuracy lab provides high-speed scanning and maximum precision and follows ISO quality standards entirely. Our coordinate measuring machines measure with uncertainty as low as 0.9+L/350 μm. Computer Aided Accuracy (CAA) corrects all dynamic influences on the machine to optimize precision even during high-speed scanning with tolerances of one micrometer or less.
Step 11
Mold Assembly
When all parts of the mold are primed and ready, they are assembled, completing the injection/die-sinking mold manufacturing process.
Step 12
Mold Trial & Testing
Place the mold into the plastic injection machine and setup proper parameters, and produce the trial run product for quality assurance & testing.
Our mandate is to leverage our resources, state-of-the-art quality assurance laboratories, and highly customizable automated manufacturing processes to consistently produce quality products and services, delivering unparalleled value to each and every one of our customers.