JZY's model JZY-Mould-478 injection mold has a Hasco, Futaba or LKM base.

Widening application base spurs equipment acquisition. Mold precision and life span remain on makers’ agenda.

China companies providing mold-making services to the electronics sector are expanding manufacturing capability, complementing initiatives for enhanced product precision and life span to match volume and quality requirements. They are riding on the back of the strong automotive, computer and communication, and home appliances markets, which respectively depend on the sector for 95, 90 and 80 percent of parts. Makers are eyeing emerging applications in the railway, aerospace, new energy, medical equipment and construction industries.

JZY Plastic Mould Ltd and BTai Industrial Co. Ltd will each add two EDMs in 2H14, with the former elevating monthly capacity to 20 sets from 15. The second supplier is planning a 30 percent boost each month as well.

Efforts to roll out high-grade molds, in turn, continue to yield large-scale models with single set weights of up to 120 tons. Variants with 0.3 to 0.5μm machining precision and those supporting 300 million to 400 million shots are included. There are also multifunction compound units that can realize multimaterial and –step forming, and complex kinds integrating intelligent control technology. Precision stamping molds, which can match 2,500rpm punch presses, are likewise part of the advanced selection.

Manufacturers generally use key CNC equipment such as machining centers, lathes and EDMs from Japan, Europe and the US. Merrich Plastic & Electronics Co. Ltd has two units of the first and 11 of the last, in addition to eight each of milling and grinding, and four wire-cutting machines. It has the V33i Vertical Machining Center, and the SP43 CNC Wire and the Edge3S Sinker EDM models from Makino.

A number of international players implement high-speed machining, concurrent and reverse engineering, virtual manufacturing and standardization. The last is an important trend in the line as adoption can improve quality, reduce costs and shorten the production cycle by 25 to 40 percent. The current local standardization grade stays at about 50 percent, still trailing the 70 to 80 percent mark of foreign counterparts. The majority of China companies follow LKM, DME, Hasco and Misumi standards to meet buyers’ requirements.

In terms of technology, CAD/CAM remains common, while some suppliers utilize CAE, CAPP, PLM and ERP. Hot runner and multiposition die methods are adopted as well.

The line in China will keep growing in coming years. Production value will rise by about 15 percent, reaching $56 billion in 2015, as a result of higher output and reduced imports. As of last year, the value of foreign-made molds shipped to the country decreased by nearly 4 percent between January and September, while the equivalent in exports climbed by 17 percent. At present, China continues to source molds overseas as the local service industry has yet to fully meet product quality and volume requirements.

In terms of sales, healthy demand will ensure about 5 percent annual growth in coming years.

The sector has more than 30,000 makers with a million-strong labor force. Production is centered in the Pearl River and Yangtze River Delta regions, which account for over a third of the country’s total yield value. The key hubs are Guangdong, Jiangsu and Zhejiang provinces, and Shanghai. There are also suppliers in the provinces of Hubei, Henan, Sichuan and Liaoning.

Typical range

China’s selection includes plastic, stamping, casting, forging, rubber, glass and powder metallurgy molds. The first two lead output with more than 80 percent aggregate share. Casting types account for 9 percent.

Products generally have 0.05 to 0.001mm precision and support 500,000 to greater than 2 million shots.

Merrich’s releases are plastic units. JZY’s range consists of plastic and stamping varieties, respectively representing 80 and 20 percent of output. At Sino-Mold Industrial Co. Ltd, plastic and casting models take up 70 and 30 percent.

Most makers offer one-stop service by providing the corresponding plastic and metal parts as well. They include JZY and Sino-Mold. BTai performs electronics parts assembly, in addition to plastic injection, metal stamping, die-casting and mold-making. It also has facilities for powder-coating metal products.

The key material is mold steel, which accounts for about 20 percent of production cost. It is categorized by cold- and hot-working die and plastic molding types.

The main varieties of the first are Cr12 (D3), Cr2WMn (01), Cr12MoV and Cr12Mo1V1 (D2), and are mostly adopted in stamping molds. Under the hot-working group are 4Cr5MoSiV1 (H13), 3Cr2W8V, 5CrNiMo and 5CrMnMo, which find wide application in casting products. In the plastic class are S50C, S45C, 3Cr2Mo (P20), 3Cr2NiMnMo (718) and 10Ni3MnCuAl.

Suppliers use local inputs for low- and midgrade molds. Baosteel, Fushun Special Steel, Changcheng Steel and Daye Steel are some of the major providers. For high-grade types, Japan, Sweden and Germany companies are the usual sources. Daido, Hitachi, Assab and Saarstahl are among them.

Prices are expected to remain at current levels until year-end, thanks to relatively stable material costs.

Related report:
Plastic parts: Suppliers boost customization, emphasize precision

Product gallery

BTai Industrial Co. Ltd
(Mainland China)

Model: BT-Mould-P0011
Delivery: 30 days
Description: 1x2 cavity; NAK-80 cavity, core, hardened to 52 HRC; LKM base; DME-standard components; 380x380x350mm; 450kg; 1 million-shot life span

JZY Plastic Mould Ltd
(Mainland China)

Model: JZY-Mould-478
Delivery: 25 days
Description: Injection type; ABS, polyoxymethylene, Rulon, PP, PC; DME, Hasco, Futaba or LKM base; S136, 718H, S130, 738H, 718 or P20 cavity, core; DME, Hasco, Yudo, LKM, Husky or Best hot runner; OEM/ ODM orders accepted

Merrich Plastic & Electronics Co. Ltd
(Mainland China)

Model: JY14616-1
Delivery: 30 days
Description: Engineering kinds of acrylonitrile styrene, ABS/PC, nylon, PE, PP, polyphenylene sulfide; one or two materials; for computer accessories, consumer electronics, mobile chargers, office equipment; ODM orders accepted

Sino-Mold Industrial Co. Ltd
(Mainland China)

Model: SMAM_1
Delivery: 40 days
Description: Injection type; ABS, nylon, nylon 66, glass-filled nylon 6, PC, PC/ABS, PE, PMMA, polyoxymethylene, PP, TPE; single cavity; LKM or S50C base; 738, 718, 718H, P20, NAK-80, S136, S136H or 420 inserts; 52±2 HRC; pinpoint, side, slim, tunnel or direct gates; 75 to 450-ton clamp force; EDM, high-polish, mirror, textured or grain finish; Yudo or Hasco cold, hot runner; UG, Pro/E, Solidworks or CAD; >1 million-shot life span