HWPD is a professional medium and large injection mold manufacturer in China with over 20 years of dedicated experience in high-precision tooling for the automotive, medical device, and industrial sectors. Our core strength lies in the design and manufacture of large-format injection molds for complex structural plastic parts — components that demand exceptional dimensional accuracy, long mold life, and consistent process stability across high-volume production runs.
We serve as a trusted long-term tooling partner to world-renowned automotive OEMs and Tier 1 suppliers. Our large injection molds are engineered to the strictest industry standards and validated through rigorous dimensional measurement and mold trial processes before delivery.
Automotive Exterior Molds | Automotive Interior Molds | Bumper & Peripheral Molds |
Engine Component Molds | HVAC System Molds | Large Structural Part Molds |
Core Business: Medium & Large Injection Mold Manufacturing
Our large injection mold manufacturing capability is built on three decades of continuous investment in precision equipment, engineering talent, and process knowledge. We specialise in molds for medium and large plastic parts — including automotive body components, structural assemblies, and functional housings — where conventional toolmakers often lack the equipment capacity or experience to deliver.
HWPD's large injection mold facility operates MIKRON high-speed CNC machining centres capable of machining mold cavities up to 2,000 × 1,200 mm. All molds are designed using professional 3D mold flow and DFM analysis, and fabricated with imported European and Japanese mold steel to achieve critical dimensional tolerances of 0.01–0.03 mm. |
Our large injection mold manufacturing technologies include:
▸ Overmolding — bonding two materials or components in a single mold cycle
▸ Two-shot (2K) injection molding — producing multi-material parts in one cycle
▸ In-Mold Decoration (IMD) — integrating surface graphics or film within the mold
▸ In-Mold Labeling (IML) — embedding labels during the injection process
▸ Hot runner systems — for large, complex molds requiring precise thermal gate control
▸ Gas-assisted injection molding — for hollow or thick-wall large structural parts
Automotive Injection Mold Expertise
The automotive sector demands the highest standards of dimensional accuracy, surface quality, and tooling durability. Over 20 years of continuous collaboration with global automotive OEMs and their Tier 1 supply chains has given HWPD an unmatched depth of knowledge in large automotive injection molds — from bumper tooling that must survive hundreds of thousands of production cycles to highly complex interior trim molds with Class-A surface requirements.
Volvo | BMW | Mercedes-Benz |
General Motors | Ford | Volkswagen |
Nissan | Honda | Toyota |
Panasonic |
Part Category | Typical Automotive Components |
Exterior Parts | Front and rear bumpers, bumper brackets and peripherals, front grilles, fenders, wheel arches, rain gutters, door handles, rearview mirror housings, automotive lamps and bezels |
Interior Parts | Door panels (front and rear), A/B/C pillars, instrument panels, glove boxes, centre consoles, overhead consoles, trunk liners |
Engine Peripherals | Intake manifolds, air filter housings, fuel rail assemblies, cylinder head covers, engine bay splash guards |
HVAC Systems | Heater box housings, air distribution ducts, blend door assemblies, evaporator covers, fluid circuit brackets |
Functional Structures | Seat back panels, spare tyre covers, underfloor shields, structural body brackets |
Large Injection Mold Achievements
Below is a selection of the large-format injection molds and molded parts HWPD has produced for internationally recognised automotive and industrial clients. These molds span bumper systems, interior structural components, and precision functional assemblies — all manufactured to OEM-specified tolerances and surface finish requirements.
Selection of large automotive injection-molded parts and molds produced for global OEM clients
Large injection mold modification and engineering change capability — extending mold service life and adapting tooling to design revisions
Large Mold Design & Engineering
Successful large injection molds begin with rigorous engineering. Because large components involve long flow paths, complex cooling requirements, and multiple slide and lifter mechanisms, poor mold design decisions compound dramatically at scale — leading to warpage, sink marks, weld line defects, and premature tool wear. HWPD's engineering team eliminates these risks through systematic design verification before any steel is cut.
Mold Flow Analysis Full Moldflow simulation covering fill, pack, cool, and warp phases — identifying gate position, fill imbalance, and cooling efficiency before tooling begins. | DFM Review Design for Manufacturability analysis covering wall thickness uniformity, draft angles, parting line placement, undercuts, and ejection strategy for large complex parts. | Cooling System Design Conformal and conventional cooling circuit design optimised to minimise cycle time and thermal distortion — critical for large, thin-wall automotive panels. |
Slide & Lifter Engineering Complex side action, hydraulic slide, and internal lifter mechanisms designed for reliable operation across millions of production cycles. | Hot Runner Integration Hot runner system design and integration for large multi-gate molds — precise thermal control eliminates cold runner waste and improves gate quality. | CAD Compatibility We accept all major 3D formats: SolidWorks, UG/NX, Pro/E, CATIA, STEP, SAT, IGES, and AutoCAD 2D reference drawings. |
Large Mold Fabrication Capabilities
Our mold fabrication facility is equipped specifically for medium and large injection mold production. All machining, EDM, and finishing operations are performed in-house under controlled conditions, maintaining complete traceability from raw steel procurement through final mold trial and delivery.
Large Injection Mold — Manufacturing Specifications | ||
EQUIPMENT & CAPACITY | MOLD PERFORMANCE | MOLD STEEL OPTIONS |
• Max Mold Size: 3,300 × 2,000 mm • Max Mold Weight: Subject to component • CNC: Priminer / Makino / WELE / YOJE • EDM: Mirror EDM + Wire-cut EDM • Grinding: Precision surface grinding • Inspection: In-house CMM + measurement reporting | • Mold Life: 500,000–1,000,000+ shots • Tolerance: Critical dims ±0.01–0.03 mm • Runner: Hot runner / Cold runner • Cavities: Single to multi-cavity • Surface: Polish / Texture (MT standard) • Delivery: With full dimensional report | • #718 / P20 — Pre-hardened structural • NAK80 — High-polish, long-life • S136 — Corrosion-resistant • H13 — High-temperature applications • 2344 / 2083 — European imported grades • Japanese Daido & Hitachi grades available |
CNC MACHINING EQUIPMENT
Working Envelope | Qty | Origin | Brand | Accuracy |
X3,300 × Y2,000 × Z1,200 mm | 1 | Germany | Priminer | ±0.02 mm |
X2,500 × Y2,000 × Z1,500 mm | 1 | China | YOJE | ±0.01 mm |
X2,500 × Y1,800 × Z1,100 mm | 1 | China | YOJE | ±0.01 mm |
X2,000 × Y1,200 × Z750 mm | 1 | Japan | Makino | ±0.01 mm |
X2,000 × Y1,600 × Z1,200 mm | 2 | Taiwan, China | WELE | ±0.02 mm |
Our Large Mold Manufacturing Process
Every large injection mold we produce follows a structured, stage-gated manufacturing workflow — ensuring engineering quality is verified at each step before proceeding:
STEP 1 DFM & Mold Flow Analysis | STEP 2 3D Mold Design & Engineering Review | STEP 3 Steel Procurement (imported grade) |
STEP 4 CNC Roughing & Semi-finishing | STEP 5 EDM & Wire-cut Processing | STEP 6 Mold Polishing & Texturing |
STEP 7 Assembly & T1 Trial Shot | STEP 8 CMM Inspection & Report | STEP 9 Customer Approval & Delivery |
Large Mold Modification & Repair
In addition to new mold manufacturing, HWPD provides a comprehensive large injection mold modification and repair service. As products evolve, engineering changes often require structural alterations to existing tooling — and for large automotive molds, this demands the same level of precision and engineering capability as original manufacture.
▸ Engineering change (ECO) implementation on existing automotive molds
▸ Cavity insert replacement and dimensional re-qualification
▸ Slide, lifter, and gate system redesign and rebuild
▸ Surface re-texturing and re-polishing to Class-A standard
▸ Cooling channel modification to improve cycle time or reduce warpage
▸ Mold life extension and preventive maintenance programmes
Plastic Materials for Large Injection Molds
Large automotive and structural injection molds at HWPD process the full range of engineering and specialty plastics, including glass- and mineral-filled grades commonly used in structural automotive components:
PP | PP+GF | PP+MD | PA6 | PA6+GF | PA66 | ABS | ABS+PC |
PC | POM | TPE | TPO | TPV | ASA | PMMA | PVC |
Large Injection Molds Beyond Automotive
While the automotive sector accounts for the majority of our large mold work, our engineering and fabrication capabilities extend to other industries requiring large or complex structural injection molds:
Medical Device Housings Large diagnostic equipment and medical instrument enclosures requiring Class-A surfaces, tight tolerances, and materials certified for medical contact. | Industrial Equipment Robot vacuum cleaner housings, floor care equipment bodies, industrial machinery covers, and large structural functional parts. | Smart Device Enclosures Large communication equipment housings, AI device structural shells, server enclosures, and precision electronic equipment structural components. |
Why Choose HWPD for Large Injection Molds
▸ Dedicated large mold engineering team with 7+ years average experience per engineer
▸ All large mold steel sourced from premium European and Japanese suppliers
▸ In-house hot runner system design, installation, and commissioning
▸ Full mold trial reporting with dimensional inspection data before customer sign-off
▸ English-speaking project management team for seamless international client communication
▸ 20+ year track record with Volvo, BMW, Mercedes-Benz, GM, Ford, Volkswagen, and Nissan
