As a senior engineer at BERGEK, an ISO 9001 certified 5-axis CNC machining manufacturer, I’ve worked on many challenging projects, but few match the technical demands of custom mold manufacturing for high-precision parts. In this case study, I’ll share how our team used advanced multi-axis CNC machining to deliver a complex injection mold with tight tolerances, intricate geometry, and full ISO 9001 traceability—demonstrating what global buyers can expect from a professional manufacturing partner.
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Case Study: Complex Mold Manufacturing with 5-Axis CNC
As a senior engineer at BERGEK, an ISO 9001 certified 5-axis CNC machining manufacturer, I’ve worked on many challenging projects, but few match the technical demands of custom mold manufacturing for high-precision parts. In this case study, I’ll share how our team used advanced multi-axis CNC machining to deliver a complex injection mold with tight tolerances, intricate geometry, and full ISO 9001 traceability—demonstrating what global buyers can expect from a professional manufacturing partner.
Project Background: Demanding Mold Geometry
Our client, a Tier 1 automotive supplier, required a mold for a multi-cavity plastic connector with undercuts, deep pockets, and multiple angles—features that traditional 3-axis machining simply could not achieve. The specification called for:
- Ultra-tight tolerance on all insert fits (±0.01mm)
- Polished core surfaces to Ra 0.8μm for flawless molded finish
- Full quality documentation and batch traceability
Engineering Process and 5-Axis Solution
- Feasibility Analysis & CAM Programming
As an ISO 9001 certified high precision mold CNC machining facility, we first evaluated the 3D model for manufacturability, then used advanced CAM software to create efficient 5-axis toolpaths for the mold cores, lifters, and inserts. - Setup & Machining
Leveraging our high-rigidity 5-axis CNC centers, we executed the entire mold core in a single clamping, minimizing errors caused by repositioning. Complex geometry machining allowed us to reach critical angles and deep features that would be inaccessible to a 3-axis mill. - Inspection and Quality Control
Every critical dimension was verified using CMMs, and surface finishes were inspected with digital profilometry. As an ISO 9001 CNC shop, we provided complete quality documentation, including FAI (First Article Inspection) reports, inspection photos, and traceable batch records.
Key Outcomes
- Precision: Every insert and moving component fit perfectly at first assembly, thanks to the stability of multi-axis CNC machining and meticulous process control.
- Speed: Single-setup machining and advanced programming reduced lead time by over 25% versus conventional methods.
- Cost Control: Though multi-axis CNC machining price is higher per hour, the efficiency gains, reduced manual rework, and lower risk of scrap kept the overall custom CNC parts cost highly competitive.
- Quality Assurance: The client received a full ISO 9001 quality package—essential for meeting automotive industry standards worldwide.
Why Choose BERGEK for Complex Mold Projects?
At BERGEK, we combine ISO 9001 certified 5-axis CNC machining manufacturer capability, deep mold engineering expertise, and global B2B service experience. Whether for prototype to production CNC cost control or complex geometry requirements, we help buyers achieve the best balance of speed, quality, and cost, with no compromise on compliance.
Contact our team to discuss your next mold or precision machining project. With BERGEK, complex is our comfort zone.
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